The digitalization of older machines remains a challenge, as they often lack modern interfaces. IoT solutions enable cost-effective retrofitting without replacing existing equipment. Cloud-native systems and real-time data analysis make legacy equipment Industry 4.0-ready, driving long-term efficiency gains.
The challenge: Digitalizing existing equipment
In manufacturing, older machines often remain essential for production. They are often robust, fully depreciated and have proven themselves over the years. However, they no longer meet modern technical standards. For example, they do not have the necessary interfaces for integration into digital systems or do not enable up-to-date condition monitoring.
A major shortcoming of modern production methods is that mechanical counters or similar traditional systems only provide basic information such as the total number of units. Data such as production speed, downtimes or other operational key figures are not available for a detailed analysis.
Replacing old machines with modern, digitalized devices is an option, but rarely practical due to the high investment costs. Companies therefore need solutions that maintain their existing infrastructure and at the same time meet the requirements of modern monitoring and data integration.
The solution: Retrofitting legacy equipment with IoT technologies
The achtBytes GmbH from Schwäbisch Hall offers an IoT platform with integrated sensors and connectivity. This enables companies to implement cloud-native condition monitoring based on real-time data by upgrading existing machines with IoT technologies. In this way, achtBytes provides an efficient and cost-effective way of bringing existing systems into the age of Industry 4.0.
Versatile sensor technology for precise data
The use of sensors enables important production data to be recorded and evaluated in real time. The flexibility of the system is particularly evident in the variety of sensor options. For example, distance sensors, current sensors, light barriers for piece counting or vibration sensors for machines with strong mechanical movements can be used.
These sensors are connected via IO-Link, which enables plug-and-play installation and easy adaptation to different machine types. The integration is carried out via a gateway (Edgebox) that processes the collected data and makes it available for further analysis. If a company has its own server infrastructure, a virtual machine can be used as an alternative. This replaces the hardware Edgebox and performs the same communication function, allowing companies with in-house infrastructure to save on additional hardware costs.
Efficient integration and flexible analysis
Custom-developed dashboards visualize the collected data, enabling flexible presentation and analysis. In addition to the quantities, the solution also records and analyzes further information such as power consumption, CO2 emissions and machine running times. This data is available both in real time and for long-term analysis and enables detailed monitoring and optimization of production processes.
A central element of the solution is the integration into existing systems such as ERP software. As a result, the production data helps with the seamless tracking and optimization of production processes. In addition to real-time monitoring, retrofitting also offers strategic advantages. The data can be used to evaluate the efficiency and energy costs of legacy machines and make informed decisions about their continued operation or replacement.
Another focus is data mobility. For example, production managers can use mobile end devices to call up the status of the systems and receive notifications in the event of problems. This functionality is particularly relevant for medium-sized companies that do not always have permanently available maintenance personnel.
The result: Sustainable competitiveness
Whether directly at the machine, on mobile devices, or centrally in the production office – the achtBytes solution provides a comprehensive overview of ongoing operations, ensuring transparency across various decision-making levels. This includes optimizing shift schedules, reducing scrap, and evaluating investments in new machines. Additionally, it enables early identification of weaknesses in the production process, allowing for targeted maintenance and minimizing downtime.
Comprehensive analysis of production processes helps companies sustainably improve operations and enhance competitiveness. Part counting serves as the foundation for data-driven management, contributing to long-term process optimization. Retrofitting older machines proves to be a cost-effective measure that lays the groundwork for sustainable competitiveness.
