On-Prem Industrial Data Acquisition for PLC Signals
Sensemation is an offline-first industrial data acquisition platform that collects PLC and device signals, exposes them through APIs, and supports production intelligence without cloud dependency.
Built for industrial environments. Designed for on-prem deployment. No cloud dependency required.
What is Sensemation?
Sensemation is an on-prem industrial data acquisition platform for collecting PLC and device signals, exposing them through modern APIs, and enabling production intelligence workflows.
It is not a full MES. Instead, it provides the reliable acquisition and integration layer needed for downtime tracking, production monitoring, shift management, analytics, and custom industrial applications.
Core focuses on reliable acquisition and exposing data through APIs; Pro/Enterprise add domain-specific modules for downtime tracking, shift management, and high-rate signal analysis.
How it Works
Connect
Configure source plugins to read PLC and industrial device signals through supported protocols.
Acquire
Collect tags deterministically through polling or event-driven group logic.
Detect Changes
Propagate only changed values to reduce unnecessary traffic and processing overhead.
Distribute
Expose real-time data through adapters such as Web APIs, webhooks, and other integration endpoints.
Industrial Use Cases
Sensemation helps manufacturers capture machine and process signals from PLCs and convert them into actionable operational data for maintenance, production, quality, and analytics.
Asset Health Monitoring
OEE Optimization
IT/OT Bridge for Analytics
Inline Quality Control
Energy Consumption Tracking
Condition-Based Maintenance
Sensemation includes
Acquisition Runtime
Flexible Triggers, Groups, and Items for fine-grained polling/event logic.
Plugin Model
Reflection-based discovery for Sources and Adapters. Easy to extend.
Change Notifications
Efficient propagation—only send data when signals actually change.
In-memory Caching
Instant access to latest values plus last N history points for trending.
Health Reporting
Built-in concepts for source online/offline status and data freshness.
Web APIs
Modern Web API adapters to read, stream, and write commands.
"Core ships with a fully offline demo using an in-memory source."
Deployment Options
Designed for on-prem reliability.
Scalable from pilot to enterprise deployment.
Sensemation Core
- Acquisition Runtime
- Plugin-based architecture
- In-memory demo source
- Web API demo adapter
- Local configuration
- Full source code access
- Offline-first operation
Sensemation Pro
- Everything in Core, plus:
- Industrial PLC connectivity (EtherNet/IP, Modbus TCP, OPC UA, etc.)
- Webhook Adapter (retry + delivery control)
- Downtime Module (running, cycle, hybrid logic)
- Shift Management (manual + scheduled rotation)
- Production Run Management
- Tracking (discrete and continuous processes)
Sensemation Enterprise
- Everything in Pro, plus:
- Event & Audit Infrastructure
- Alarm Engine (rules, acknowledgment, escalation)
- Trending / Historian capabilities
- Advanced reporting foundations
- High-rate data modules (per-piece curves, continuous capture)
- Custom integration & deployment support
Why industrial teams choose Sensemation
Sensemation is licensed for on-prem deployment and does not require cloud connectivity.
Modular Architecture
Sensemation is built as a highly extensible platform, allowing you to grow from reliable acquisition to advanced analytics.
Core Foundation
- Acquisition Runtime
- Plugin-based Sources & Adapters
- Canonical Signal Model
- Offline-first Architecture
- WebAPI Exposure
Sensemation Core provides a stable, extensible foundation for industrial signal acquisition and distribution.
Operational Intelligence (Pro)
- Downtime
- Shift Management
- Production Runs
- Tracking
- Industrial Connectivity
Sensemation Pro builds on the Core foundation by adding operational modules designed for real production environments.
Advanced Intelligence (Enterprise)
- Alarms & Events
- Trending & Historian
- Domain Event Models
- High-Rate Data (Per-Piece Curves)
- Advanced Analytics
Sensemation Enterprise extends the platform with advanced industrial analytics and high-frequency data capabilities.
Frequently Asked Questions
No. Sensemation is not a Manufacturing Execution System. Sensemation focuses on reliable signal acquisition and structured production intelligence modules. It provides a clean, extensible foundation for downtime tracking, production management, and advanced analytics without the overhead of a full MES platform.
No. Sensemation is designed for on-prem deployment and can operate fully offline. No cloud services are required for acquisition or operation.
In most cases, no. Sensemation is designed to read existing signals from PLCs and industrial devices. The goal is to leverage available data without requiring invasive PLC logic modifications. Some use cases may benefit from additional signals, but changes are not mandatory for basic deployment.
Sensemation Core includes: Acquisition Runtime, Plugin-based architecture, Change-only signal propagation, In-memory demo source, Configuration system, and Offline-first operation. It does not include industrial PLC drivers or business modules such as downtime or production management.
Sensemation Pro includes everything in Core plus: Industrial PLC connectivity (e.g., EtherNet/IP, Modbus TCP), Reliable webhook adapter, Downtime module, Shift management, Production run management, and Tracking for discrete and continuous processes. Pro is designed for real production environments.
Sources are designed to automatically detect disconnections and attempt reconnection. The system exposes health and status information so that upstream systems and operators can detect stale or offline data conditions. Reliability is treated as a first-class concern.
Sensemation uses a change-only propagation model. Signals are distributed when their value changes, reducing unnecessary traffic and ensuring efficient sub-second updates.
Yes. Sensemation is designed to expose acquired signals through APIs and adapters, enabling integration with: Internal services, Workflow engines, Reporting tools, and Custom applications. Integration capabilities expand further in the Pro and Enterprise editions.
The Core version focuses on standard acquisition workloads. Enterprise capabilities extend the platform to support high-rate data scenarios, such as per-piece curves and high-frequency sampling use cases.
Sensemation is designed for: Industrial automation engineers, Production and plant managers, Engineering teams responsible for data acquisition, and Organizations seeking structured production intelligence without cloud dependency. It is particularly suited for environments where reliability and on-prem control are critical.
SCADA systems focus primarily on visualization and control. Sensemation focuses on structured, reliable signal acquisition and production intelligence architecture that can integrate into broader industrial software ecosystems.
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