Page 46 - Packaging News Jan-Feb 2020
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INDUSTRY 4.0
When old meets new
2CONNECTIVITY
Legacy machines were designed for one-on-one connection and communication with a PLC. These outdated systems do not support the multiple data points required by modern IoT systems. Although add- ing a data mining layer can enable them to report basic performance information, it probably won’t help with predictive and ongoing mainte- nance reporting – which may need additional sensors – or scalability.
3REPORTING
Legacy system interfaces tend to be hardcoded for reporting, usually via spreadsheets. The facility for custom data acquisition cannot sim- ply be added through access to the IoT, it needs to be programmed in.
4REMOTE MANAGEMENT
One of our clients recently jok- ingly said he’d like to be able to re- motely monitor his company’s entire new production line from an iPad while sitting on a houseboat. While we supplied him with that capabili- ty, it’s an easier thing to deliver on an all-new production line. It requires a level of access to data that a simple data mining protocol over older equipment doesn’t deliver.
5COST
Even a simple cloud protocol can involve upgrading the control sys- tems on older equipment. Request- ing every OEM (original equipment
CEO of integration and automation specialist Foodmach, Earle Roberts, outlines key things you should know about applying Industry 4.0 in your factory, especially where legacy equipment is involved.
NDUSTRY 4.0 supports better busi- ness decision making through the acquisition of real-time data into intelligent ERP (business manage- ment software).
The major challenges facing manufacturers as they introduce Industry 4.0 to their production lines are around budgets, internal expertise and older equipment or
legacy systems.
Most established factories con-
tain legacy machines of varying ages, PLCs, and robots of one type or another. Each older machine may have a different legacy proto- col, making it difficult to connect them to an IoT solution that will mine all their valuable data. Legacy systems have not been de- signed or programmed to scale up,
accommodate extra data points, or connect to the cloud.
It may not be enough to use a band- aid approach by layering a simple data mining protocol on top of old equipment to create an Industrial Internet of Things (IoT) solution. The potential downsides of doing this touch on five key areas:
1
SECURITY
Adding cloud functionality to a system with no security for remote connectivity is an obvious security risk. A user name and password with basic authentication may not be enough to prevent unwanted access. Systems made for IoT integration will employ high-performance au- thentication, encryption, and access rights management technologies.
Old and new equipment was integrated with a line control system for the Yalumba Wines line upgrades.
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