MES, API & IIoT Integration

Problem

Production counts and downtime still depended on manual entry. The plant needed a cybersecurity-reviewed edge device that could read digital pulses and analog signals and hand them to L2L and Ignition Edge without a clipboard on the line.

Approach

Revolution Pi became the nervous system of the floor: a locked-down image, pulse and analog capture, and a documented path into Leading2Lean plus Ignition Edge. The point was a playbook other plants could copy, not a one-off panel.

Architecture

Field pulses and analog loops terminate on a reviewed RevPi image. Node-RED / Python translate counts to engineering units, then fan out to L2L REST and Ignition Edge — no operator keying.

Implementation

Pulse totals become production quantity in one function. The REST client posts a sanitized payload and treats timeouts as a buffer, not a lost count, so a MES hiccup does not erase what the sensor already saw.

def pulse_delta(current, last, rollover=65535):
    delta = current - last
    if delta < 0:
        delta += rollover + 1
    return delta

def publish_count(session, machine_id, pulses, duration_s):
    payload = {
        "machine": machine_id,
        "quantity": pulses,
        "duration_s": duration_s,
    }
    response = session.post("/api/v1/production", json=payload, timeout=5)
    response.raise_for_status()
    return response.status_code

Results