A common belief persists: old machines are viewed as obstacles to connectivity and digital integration. However, this idea is a myth. This article explores why all machines, whether old or new, can be integrated into a connected production system.
Connectivity in Industry 4.0 relies on the ability of equipment to exchange data through standard communication protocols or custom solutions. This includes the capture, analysis, and utilization of data to improve the efficiency of production processes.
It is often said that only modern machines are ready for connectivity due to their integration with technologies like the Internet of Things (IoT). Yet, this perception does not take into account the reality where equipment can be decades old and still remain fully operational.
In fact, old machines, like new ones, possess sensors and electrical systems that allow for intercepting and transmitting data. You may wonder how this is possible. The majority of machines, regardless of their age, operate with standard electrical signals that can be used to transmit information.
Connecting old machines comes with certain challenges, including the frequent absence of technical documentation and detailed electrical diagrams. However, their less sophisticated technology offers unexpected benefits. Simpler electrical systems make it easier to identify relevant signals for connection, unlike modern machines which often incorporate complex multi-layered electronic systems. This relative simplicity allows for a more direct approach in identifying and utilizing essential connection points.
For old machines, custom solutions may include the installation of external IoT modules or signal conversion devices that translate electrical data into usable digital information. These approaches ensure that even the oldest equipment can integrate into a modern digital architecture. A particularly effective option involves programming a new output from an existing PLC through ladder diagrams, thus gaining access to additional data without altering the machine's hardware infrastructure.
In conclusion, believing that old machines hinder connectivity is a myth. With current technologies, almost any machine can be integrated into a connected production network. The key is to recognize that a machine's age does not indicate its capacity for connectivity. As long as there is electricity in a machine, it is connectable. By adopting an innovative approach and leveraging retrofitting technologies, companies can fully capitalize on their existing equipment in the transition to Industry 4.0.
To explore further, consider an assessment of your machine park to uncover connectivity opportunities and take full advantage of available connectivity solutions.
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