Point-table-less PLC Device
Intelligent Protocol Detection · Full-plant Data Collection & Networking

II. Core Pain Points

No point table and multi-brand heterogeneity make legacy PLC data collection & networking impossible from the very first step.

• No point table, no starting point for integration: Legacy PLCs have no documentation and vendors do not cooperate; the first step of traditional acquisition — "obtain register addresses" — cannot be done, as no one knows which controller and which address hold the parameters.
• Multi-brand heterogeneous PLCs: Different brands and series such as Mitsubishi, Siemens and OMRON use different protocols; per-device custom development is costly and lengthy, and on-site engineers cannot fully cover all of them.
• Broken MES quality traceability: Without parameter acquisition, the production process cannot achieve one-item-one-code quality traceability and quality control; when a quality deviation occurs, it is hard to trace back to the specific equipment and time period.
• No run monitoring for the equipment department: Equipment working status is a black box; faults rely on manual inspection, and downtime losses are hard to locate in time; the equipment department lacks a unified run-monitoring platform.

IV. Solution: G160 Protocol Detection + Serial Splitter

Without relying on a point table, use "monitoring + protocol analysis" to automatically identify the register addresses of HMI parameters, completing acquisition.

• Serial splitter connection — parallel and non-intrusive: Insert a splitter module in series between each serial PLC and HMI; G160 is connected in parallel on the communication line, without modifying the original wiring and programs — plug-and-play.
• Real-time communication-packet monitoring: G160 captures the interaction packets between the PLC and HMI in real time, without changing any logic on either side; the original HMI display and operation are completely unaffected.
• Protocol analysis automatically identifies register addresses: Through protocol parsing, it automatically scans and identifies the register addresses corresponding to parameters displayed on the HMI, building a "parameter–address" mapping without any point table.
• HMI-visible means acquirable: Any parameter visible and operable on the HMI can be identified and acquired through this method, completely bypassing the "no point table" roadblock.
• 45 devices equipped one by one for full-plant networking: On site, 45 devices are deployed with G160 + splitter one by one and uniformly uploaded to the platform, achieving full-plant data collection & networking and centralized management.

VI. Why AIS-G160

The two capabilities — "splitter parallel monitoring + protocol-analysis auto-identification" — exactly match all the demands of point-table-less acquisition for legacy PLCs.

• Monitoring without intrusion: The splitter is connected in parallel on the PLC–HMI communication line, with zero modification to the original programs and wiring; 10+-year-old legacy equipment is accessed with zero risk.
• Protocol-analysis auto-identification: Automatically scans the register addresses corresponding to parameters displayed on the HMI, eliminating the point table and vendor cooperation, solving the source problem of "where the parameters are."
• Legacy models also supported: Built-in 500+ industrial-protocol driver library; old models such as Mitsubishi FX2N/FX3U/FX5U, Q series, Siemens S7-200 SMART, OMRON CJ are plug-and-play.
• LAN remote O&M: After deployment, the PLC can be accessed remotely within the LAN, enabling a degree of remote debugging and O&M, reducing on-site travel.

VIII. PLC (Programmable Logic Controller) Brands & Models Supported by G160

This case centers on G160 connecting to legacy PLC-controlled equipment. AIS-G160 has a built-in library of 500+ industrial-device protocol drivers. The following are mainstream PLC brands and models verified for data acquisition (some models require on-site interface confirmation), serving as a basis for solution selection and field verification.