Here’s an example of how a manufacturing company could connect their legacy machines with modern IoT tools, using the strategies and solutions mentioned above:
Scenario: A manufacturing company has a legacy CNC (Computer Numerical Control) machine on their factory floor that utilizes the Modbus communication protocol. The company wants to integrate this legacy machine with their modern IoT system, which uses MQTT (Message Queuing Telemetry Transport) as its communication protocol.
- Protocol Converters: The company can use a Modbus-to-MQTT protocol converter to translate data between the legacy CNC machine and the IoT system. The converter would be connected to the CNC machine and configured to translate data from the Modbus protocol to the MQTT protocol, enabling seamless communication between the two systems.
- IoT Gateways: The company can implement an IoT gateway that supports both Modbus and MQTT protocols. The IoT gateway would be connected to the CNC machine and configured to communicate using the Modbus protocol. The gateway would then transmit the data to the IoT system using the MQTT protocol, enabling seamless data exchange between the legacy machine and the IoT tools.
- Retrofit Kits: The company can retrofit the legacy CNC machine with a kit that includes sensors, actuators, and a communication module supporting the MQTT protocol. By installing the retrofit kit on the CNC machine, the company can modernize the machine’s communication capabilities and make it compatible with the MQTT-based IoT system.
- Middleware Solutions: The company can implement a middleware solution that sits between the legacy CNC machine and the IoT system. The middleware would be responsible for translating data from the Modbus protocol used by the CNC machine to the MQTT protocol used by the IoT system, enabling seamless communication between the two systems.
- Custom Integration: If none of the off-the-shelf solutions are suitable for the specific requirements of the legacy CNC machine and the IoT system, the company can develop a custom integration solution. This may involve creating a custom hardware adapter that translates data between the Modbus and MQTT protocols or writing custom software that handles the communication and data translation between the two systems.
By using one or more of these strategies and solutions, the manufacturing company can successfully connect their legacy CNC machine with their modern IoT tools, enabling real-time data exchange and insights, improving overall production efficiency, and making data-driven decisions to optimize the manufacturing process.
Retrofit kits available on the market
There are retrofit kits available on the market that can help modernize legacy machines and make them compatible with IoT systems. Here are two examples of retrofit kits that can be used for different types of legacy machines:
- eWON Flexy: The eWON Flexy is an industrial IoT gateway and data acquisition system that can be used as a retrofit kit for legacy machines. The Flexy supports a wide range of communication protocols, such as Modbus, Ethernet/IP, and Profibus, making it suitable for various types of legacy machines. The Flexy can be configured with different extension cards, allowing you to add specific features like additional Ethernet ports, serial interfaces, or cellular connectivity. By installing the eWON Flexy on a legacy machine, you can enable IoT connectivity, remote monitoring, and data collection from the machine.
More information: https://www.ewon.biz/products/ewon-flexy
- Balluff IO-Link Retrofit Kits: Balluff offers various IO-Link retrofit kits that can be used to modernize legacy machines and make them compatible with IoT systems. These kits include IO-Link sensors, IO-Link masters, and IO-Link accessories, which can be installed on the legacy machine to enable IoT connectivity and communication with modern automation systems. By retrofitting a legacy machine with Balluff’s IO-Link components, you can enable features like condition monitoring, predictive maintenance, and process optimization.
More information: https://www.balluff.com/en/de/industries-and-solutions/technologies/io-link/io-link-retrofit-kit/
These retrofit kits are just two examples of the many solutions available on the market. When selecting a retrofit kit for your specific application, it’s essential to consider factors such as the communication protocols used by your legacy machine and IoT system, the required functionality, and the compatibility of the retrofit kit with your equipment.
Example for the Protocol Converters
There are several protocol converters available on the market that can help bridge the communication gap between legacy machines and modern IoT tools. Here are two examples of protocol converters that support different communication protocols:
- Anybus Communicator: The Anybus Communicator is a family of protocol converters that enable communication between devices using different communication protocols. These converters support various industrial protocols, such as Modbus, Profibus, DeviceNet, Ethernet/IP, and CANopen, among others. By connecting an Anybus Communicator to a legacy machine and configuring it to translate data between the specific protocols used by the machine and the IoT system, you can enable seamless communication between the two systems.
More information: https://www.anybus.com/products/gateway-index/anybus-communicator
- Moxa MGate Series: The Moxa MGate Series offers a range of industrial protocol converters that support multiple communication protocols, such as Modbus, EtherNet/IP, PROFINET, and DNP3. These converters are designed for various applications, including connecting legacy devices to modern automation systems and enabling data exchange between devices using different protocols. By using a Moxa MGate protocol converter, you can bridge the communication gap between a legacy machine and an IoT system and enable seamless data exchange between them.
More information: https://www.moxa.com/en/products/industrial-network-infrastructure/protocol-gateways
These protocol converters are just two examples of the many options available on the market. When selecting a protocol converter for your specific application, it’s important to consider factors such as the communication protocols used by your legacy machine and IoT system, the required data translation capabilities, and the compatibility of the converter with your equipment.
