A flexible, drop-in smart gateway for modern energy management
Abstract
The SECO Modular Link MX93 is a flexible, drop-in smart gateway for large-scale Industry 4.0 retrofits in sectors like smart energy metering.
Increasing regulatory pressure is driving installation of smart meters globally. For example, in 2025 the German government mandated 95% smart metering coverage by 2030. However, the ROI of replacing thousands of legacy gateways is not obvious, especially for energy suppliers funding large-scale upgrades. Modern smart energy gateways address this ROI dilemma by combining modular industrial PCs, comprehensive connectivity, and built-in edge analytics in a single solution for business value and IoT capability. Retrofitting existing deployments with these gateways unlocks measurable value and transforms aging infrastructure into dynamic Industry 4.0 environments.
Comparing traditional and smart metering gateways
Traditional smart metering infrastructure consists of many meters connected through data concentrator units (DCUs) forwarding raw data to a head-end system (HES) that manages and validates network traffic. This centralized architecture presents barriers for providers seeking infrastructure improvements.
| Requirement | Traditional Gateway | Smart Metering Gateway | Cost/Benefit of Migration |
|---|
| Integrating modern IT with legacy field buses | Supports limited fieldbus protocols; needs middleware for cloud integration | Flexible I/O, native IoT protocol support | Less integration time and middleware costs |
| Adding local intelligence without inflating costs | Minimal processing; remote analytics; high bandwidth | Edge processing, local anomaly detection | Higher hardware cost, but lower transmission/cloud expenses |
| Ensuring long-term reliability and security | Limited encryption and remote update; rare firmware upgrades | Industrial-grade design, hardware security, OTA updates | Lower maintenance, compliance risk, and cyber vulnerability |
| Preserving investments in legacy meters and sensors | Fixed functionality, I/O changes mean full replacement | Configurable ports/interfaces for legacy support | Reuses wiring/sensors, extends infrastructure value |
The Modular Link MX93: Advantages and features
The Modular Link MX93 is an industrial PC based on NXP i.MX 93 multicore processor, integrating hardware acceleration for AI inference and a secure enclave for enhanced security. These enable lower OPEX—edge computing minimizes network transmission, OTA updates enable remote patching and less costly maintenance. For legacy meter interfacing, the gateway offers Ethernet, USB, RS-232/422/485 via RJ12; Wi-Fi/LTE options for wireless deployment. Its compact, fanless case supports industrial temperature range and flexible mounting (including DIN rail).
Its true strength is modularity: compatible daughter cards allow expansion for additional I/O or communication, letting smart suppliers incrementally tailor their system without replacing base hardware.
Integration procedure
- Assessment: Inventory meters/sensors/gateways, protocols, power supplies, mounting, identify bottlenecks (bandwidth, management, security).
- Protocol/data translation: Build software bridges from legacy fieldbus to modern IoT protocols; SECO’s Clea software framework included.
- Security/device management: Switch on secure boot, encryption, firewall via processor’s secure enclave; enroll in OTA management for updates/monitoring (EdgeLock 2GO).
- Edge analytics: Deploy local analytics for load forecast and anomaly detection.
- Phased rollout: Pilot test, then gradual expansion running new/old gateways to verify data before replacing legacy units.
- Lifecycle management: Harmonize configuration, update scheduling, adopt predictive maintenance, add modular features.
Cost-benefit and ROI analysis
| Metric | Value | Notes |
|---|
| Upfront capex increase | ≈ US $300,000 | Additional Modular Link MX93 compared to basic gateway |
| 5-year Opex savings | ≈ US $3.9 million | Less maintenance, bandwidth, downtime; OTA updates, predictive maintenance |
| Net savings (5-year) | ≈ US $3.6 million | Opex savings minus capex |
| Payback period | ≈ 18 months | Time required to recover investment |
| ROI (5-year) | ≈ 440% | Net savings / capex x 100 |
Conclusion
A phased smart gateway rollout based on Modular Link MX93 can achieve ROI in just 18 months and five-year payback up to nearly 450%. It’s a scalable, secure, modular solution for stable energy management and the transition to Industry 4.0.
Want more details? Contact SECO and start your smart gateway retrofit journey.