In modern manufacturing, the digital networking of machines with systems such as MES, MDE and BDE is crucial for transparency and efficiency. In general, all machines, no matter how old, can provide valuable information – if they are integrated into the data acquisition system.
Below we present the four most common connection options – from the ideal case to the pragmatic solution.
Connecting old and new machines digitally
So gelingt der Rollout von BDE, MDE und MES1. Ideal case: The machine speaks OPC UA
Newer machines are often already equipped with an OPC UA interface. This means:
- Simple integration
- Standardized data exchange
- Little effort for IT and automation
Benefit: Fast productivity, low maintenance, high data quality.
2. Upgrade via the control system
Some machines can be connected directly to OPC UA via an upgrade or extension module – for example by::
- Firmware Extensions
- Upgrade cards from the controller manufacturer
Benefit: High-quality control data with minimal intervention in the hardware.
However, you should bear the following in mind: This upgrade is often expensive and it is worth considering the following options.
3. Middleware: The smart bridge to the machine
If no OPC UA module is available, there is a clever solution: communication middleware. Providers such as Kepware or Softing offer gateways that communicate with the machine controller and output the data as OPC UA.
Advantages:
- No conversion work on the machine
- Many control types supported
- Scalable for entire machine parks
- Access to the machine´s process parameters
Benefit: Standardized data connection for existing control systems – without major intervention.
4. Retrofit: retrofitting with sensor technology
In contrast to retrofitting with sensors, the solutions described above offer access to all PLC data – including extensive process parameters, which are becoming increasingly important in the age of AI-supported data analysis. However, if communication with the control system is not possible, external sensor solutions are another useful option. By attaching sensors to the machines, the requirements for production data acquisition can be fully covered:
- Cycles/quantity signals
- Downtimes
- Running times
For cycle times of less than one minute, a single signal can provide all of the above information, as a standstill can be assumed if there is no cycle or quantity signal.
The signals are digitized via IO modules or simple gateways and transferred to the MDE/MES system.
Benefit: Even very old or simple machines provide basic data – ideal for OEE, basic fault analyses or simple PDA masks.
Conclusion: Every machine can be a data provider
Whether a high-tech system or a machine from the very beginning – with the right solution, you can integrate any machine into your digital production world.
Cosmino supports you with the right PDA, MDA and MES solutions – including consulting, integration and operation.
This is how to get the best out of your machinery – no matter how old it is.