Ruggedised edge gateways
Linux gateways that survive dust, heat, and power cuts, with local buffering and store-and-forward delivery so a dropped link never loses a message.
Hardware
Industrial IoT & Connected Edge Architecture
Most industrial data dies on the sensor. We build the edge layer that turns floor telemetry into decisions your enterprise systems can act on.
Overview
Industrial environments generate enormous amounts of data: machine states, temperatures, counts, weights, faults. Most of it dies on the sensor. The gap is rarely the hardware. It is the unglamorous engineering in between: edge gateways that survive dust and power cuts, protocols that do not speak HTTP, and networks that were never designed for telemetry.
Lexylon's industrial IoT consulting practice builds that middle layer for warehouses, plants, and logistics operations across Australia. We design edge computing architectures that speak the languages of the floor, from Modbus and OPC UA to serial and the vendor dialects nobody documents, normalise the data locally, and stream it through real-time telemetry pipelines into your enterprise systems. Custom laser-scanner and smart warehouse hardware integrations connect the physical movement of stock directly to your inventory logic.
Edge-first design means the site keeps operating when the link drops: local buffering, store-and-forward delivery, and on-gateway logic for decisions that cannot wait for a round trip. Combined with anomaly detection on live telemetry and predictive maintenance signals, the result is operational data you can act on, not just store.
Lexylon is also one of the few Australian partners that designs the hardware itself. Our Melbourne on-site team spans hardware, electronics, firmware, and software engineers, so a custom sensor device can travel from schematic and PCB layout through industry grade testing to a Bluetooth-connected native mobile app without leaving one roof. Delivery is complete by design: Gerber files, schematics, the bill of materials, and pick and place documents are handed over with the firmware, and the design belongs to you, including the right to patent it.
The proof
Architecture & tech stack
Protocol normalisation
Modbus, OPC UA, serial, and the undocumented vendor dialects, translated at the edge into one clean, typed telemetry stream.
Durable telemetry pipelines
MQTT into time-series storage through authenticated, monitored pipelines with the reliability of any other production workload.
Scanner & hardware integration
Zebra and Honeywell laser scanners wired directly into your inventory logic, so a scan on the floor is a transaction in the system.
Custom sensor hardware and PCB design
Schematic capture, PCB layout, prototype runs, and industry grade testing, engineered by our Melbourne team. The finished design pack is yours outright.
Bluetooth devices with native mobile apps
BLE communication between custom hardware and iOS and Android apps, with over the air firmware updates delivered through the app itself: staged rollouts, automatic rollback, no truck required.
Industrial reality
Engineered for Australian sites, not lab conditions
Demos work on office wifi. Australian operations run in tin sheds in February heat, at sites hours from the nearest technician, on links that drop without warning. We design for that version of reality first.
Keeps working when the network does not
Gateways buffer locally and reconcile when the link returns, so a remote site can run itself for hours or days and the record still ends up complete.
From forklift scanner to boardroom dashboard
One path from a scan on the floor to WMS, ERP, and live dashboards: stock movements visible in seconds, patterns visible across months.
Predictive signals, not data graveyards
Anomaly detection and predictive maintenance models watch the telemetry, so a failing bearing becomes a scheduled job instead of a Saturday call-out. The models can run onshore, beside everything else.
Execution methodology
01
Site survey and protocol audit
We identify every data source on the floor, from PLCs and sensors to scales, scanners, and legacy controllers, plus the protocol each one actually speaks and the environmental constraints that shape the design.
02
Gateway and pipeline build
Ruggedised gateways normalise and buffer data locally, then stream it into AWS ingestion provisioned with Terraform. Every message is durable: power cuts and dropped links lose nothing.
03
Integration and AI-driven rollout
Telemetry lands in your systems, from WMS and ERP to dashboards and maintenance platforms, with anomaly detection and alerting tuned alongside the people who respond to it, so alarms mean something.
What you get
- Edge computing architecture & gateway deployment
- Real-time telemetry pipelines with durable delivery
- Laser-scanner & warehouse hardware integrations
- Protocol integration (Modbus, OPC UA, serial)
- AI-driven anomaly detection & alerting
- Live operational dashboards & historical analytics
- Complete hardware design pack (Gerbers, schematics, BOM, pick & place)
Tools & platforms
- Edge Linux gateways
- MQTT
- Modbus / OPC UA
- Custom PCB / BLE / Embedded firmware
- Zebra & Honeywell scanners
- AWS IoT / Terraform
- Time-series storage
FAQ
Industrial IoT questions we hear most
Can you connect our older machines and PLCs?
Yes. We read Modbus, OPC UA, serial, SCADA outputs, and the undocumented vendor protocols in between, translated at the edge without replacing your equipment.
What happens to the data when the internet drops at a site?
Nothing is lost. Gateways buffer locally with store-and-forward delivery, operations continue on site, and the record reconciles automatically when the connection returns.
Which scanners and warehouse hardware do you support?
Zebra and Honeywell scanners, scales, label printers, and custom laser-scanner rigs, all wired into your WMS, ERP, and inventory logic so a scan is a transaction, not a spreadsheet entry.
Can the sensor data feed AI, like predictive maintenance?
Yes. We run anomaly detection and forward looking maintenance signals on live telemetry, and the models can operate inside Australia alongside the rest of your stack.
Do you work on sites outside the metro areas?
Yes. Edge-first design assumes remote connectivity from the start, our Melbourne and Sydney teams travel to site, and 24/7 remote monitoring covers the hours when nobody is there.
Can you design and build custom sensor hardware for us?
Yes, end to end: schematic, PCB layout, prototyping, and industry grade testing. You receive the full design pack, Gerbers, schematics, BOM, and pick and place files, and the intellectual property, including patent rights, belongs to you.
Can devices update their firmware in the field?
Yes. Over the air updates ship through the companion mobile app over Bluetooth, released in stages with automatic rollback if an update misbehaves.
Engagement models
Three ways to engage, one transparent cost structure
Site rollouts price well as fixed modules per facility, with time and materials covering the integration long tail.
Dedicated team
A stable squad of Lexylon engineers reserved for your roadmap, month after month. Predictable capacity, a predictable invoice, and a team that compounds knowledge of your business.
Time and materials
Pay only for the hours worked, at some of the most competitive rates in the Australian market. Ideal when scope moves, with timesheets you can read and question line by line.
Project or module based
A fixed price built up from an honest effort estimate in hours, module by module. You see exactly how the number was reached before you sign, and it does not move unless the scope does.
Contact
Ready to hear what your machines are telling you?
Your first discovery session is free. Tell us about your platform, your constraints, and where it hurts; we analyse the problem and come back with a proposed solution, no obligation.
Or email us directly at hello@lexylon.com