Smart Card acts as a data bridge between different applications
27 November 2025 
ABB has used the SPS exhibition in Germany to launch a device that bridges the gap between field devices, controllers and sensors, and local IT systems or the cloud. The Smart Communication Card is aimed at decentralised applications that generate a wealth of operational data that usually goes unused because it’s difficult to transfer from the field level to IT or cloud systems. The problem is compounded by machines and controllers that use different protocols, while isolated components and a lack of interfaces further complicate integration.
The Card brings intelligence and connectivity to applications that lack a central control system. By connecting OT (operational technology) with IT, data becomes immediately available in the cloud. Users can capture and process this data in real time, for applications such as monitoring, targeted maintenance, and improving process efficiency.
The ability to analyse operational data in real time and use it for intelligent decision-making offers significant potential – whether in building technology decentralised pumping stations.
As a compact edge communication device, the Card connects local components to local servers or cloud systems – without needing additional gateways or industrial PCs. It captures data such as measured values and status messages at the field level and prepares them for further processing.
Communication with controllers, measuring devices, and protection devices is simplified by using standard protocols such as OPC UA, Modbus RTU, and TCP. The Card enables easy integration with higher-level platforms for condition monitoring, alarm notification, or automated analysis via MQTT or HTTPS.
“With the Smart Communication Card, we are building a manufacturer-independent bridge between different applications and data,” explains Sven Glöckler, OEM segment manager at ABB Electrification. “It is the key to greater efficiency, security and digital resilience in industry.”
The Node-RED open-source platform is built in, allowing users to create data flows, simple logic, and visualisations in Web browsers, without needing any programming knowledge. They can connect pre-built function blocks to create customised workflows via a drag-and-drop interface.
This allows users, for example, to visualise temperature trends in HVAC systems, report pump malfunctions automatically, or analyse energy consumption in mobile applications.
Thanks to its compact design, Web-based configuration, and support for open standards, the Smart Communication Card can be integrated into new projects or retrofitted to existing systems. It connects via common interfaces such as Ethernet or RS-485, without needing extra software, hardware or gateways. The Card is compatible with devices from a variety of manufacturers and can be used, for example, in conveyor systems or HVAC systems.
It is said to save time and costs. Existing hardware doesn’t need to be replaced, but can be expanded intelligently at a fraction of the cost. Protection mechanisms ensure secure operation: encrypted data transmission, a built-in firewall, secure booting, and role-based user management, protect communication and device software from unauthorised access and manipulation. In this way, the Card creates trustworthy connections between production and IT, even in environments with high security requirements.
A typical application for the Smart Communication Card will be condition-based monitoring of decentralised systems such as pumping stations. It will record operating and condition data continuously, detect deviations, and warn of potential wear or malfunctions, allowing targeted and proactive maintenance planning, thus preventing downtime and significantly increasing availability.
It can also be used to analyse energy consumption data either locally or in the cloud, helping to identify peak loads, compare consumption patterns, and optimise energy use.
The Card brings intelligence and connectivity to the field level of industrial and decentralised systems. It makes previously unused data available, thus creating the foundation for improved efficiency and control, and lower operating costs.
