PECM Issue 33 2018 | Page 52

RETROFIT YOUR FUTURE

AUTOMATION INDUSTRY 4.0

EU AUTOMATION
RETROFIT YOUR FUTURE
You can ’ t teach an old dog new tricks . In almost every country , an expression exists to mean that it ’ s difficult to change the way something is done , if it has been that way for a long time . Despite the popularity of the phrase , it does not apply to industrial machinery . Retrofitting allows legacy equipment to learn new tricks at an impressive rate .
Here , Jonathan Wilkins , marketing director at supplier of industrial obsolete parts EU Automation , explains why retrofitting is so important to Industry 4.0 .
Industrial machinery has a long lifespan . In many facilities , equipment will be in operation for 15 to 30 years , as it is designed to be robust and long-lasting . Legacy equipment can function effectively for decades , but its capabilities will fall behind newer counterparts .
Older machines or components may be less efficient , have less computing power and less memory to store and record data . They could also offer limited connectivity and may even operate with a different language protocol . These differences can make it difficult to make outdated equipment compatible with new industrial computers or programmable logic controllers ( PLCs ).
Limited connectivity , communication and data storage creates a barrier to Industry 4.0 . For a factory to be truly smart , machines must be able to communicate and make real-time decisions . This requires networking between individual components , machines , factories and even enterprises to collect , communicate , analyse and compare data . This information can then be used for predictive analytics or to optimise processes .
Monitoring equipment ’ s efficiency and using advanced diagnostics means machinery will be less likely to cause unplanned downtime . Facilities relying on aging , unconnected infrastructure can suffer huge production losses if components fail and manufacturing is halted .
Retrofitting to Industry 4.0
The advantages of Industry 4.0 are vast . Connected factories can be made more flexible , be monitored remotely , offer an improved workplace for staff , facilitate predictive analytics and more . The bottom line is that data must be gathered , turned into information and communicated to achieve this .
52 PECM Issue 33
Thankfully , these capabilities don ’ t have to be built into a machine , meaning that if you want to reap the benefits of Industry 4.0 , you don ’ t have to build an entirely new factory . This is good news , particularly for small and medium enterprises ( SMEs ), who are unlikely to be able to afford large amounts of new equipment .
Retrofitting adds new capabilities or functions to equipment , that it didn ’ t have when originally designed and built . It could be a case of adding a connected sensor to a motor , or replacing older components with new , more advanced equipment . One of the most popular ways to do this is to add flexible modular devices to capture , process and transfer data .
Retrofitting has become a large market , as it can improve energy efficiency , processing speeds , machine reliability , reduce the need for maintenance and extend system life . For example , Bosch Rexroth has used its Internet of Things ( IoT ) gateway to reduce costs by 25 per cent at one of its German facilities , by fitting production test risks , which took only four hours to fit . To get the most out of retrofitting , it should be a gradual and managed process .
What ’ s the catch ?
Though retrofitting makes it possible to connect legacy equipment to the Industrial Internet of Things ( IIoT ), it can be challenging to implement across a facility . Old equipment can be difficult to digitalise and connect , as they were not designed to do so . Some legacy equipment may be poorly documented or understood , which can leave some uncertainty about what the consequence of a retrofit will be .
Because equipment in factories has often come from different vendors and operates to different communication platforms , it can be difficult to connect it to the system and to each other . Interoperability can therefore be a huge hurdle for companies migrating to smarter methods of production . Engineering staff must maintain a huge amount of knowledge to optimise heterogenous systems .
Manufacturers must take security into account when retrofitting , because adding a new application to an old system could introduce security risks if the system was not designed to be connected to the internet .
Where do I start ?
Well structured retrofitting , rather than random patching , is the best way to future proof your upgraded factory . Simply monitoring whether equipment is on or off and how much the system is producing can give you an indication of effectiveness and performance .
One example is the Pepperl + Fuchs smart bridge adapter , which enables process data collected by field devices to be communicated with a mobile device via Bluetooth .
This connects information which would usually have remained in the machine to facility staff , who can then make use of it in maintenance .
Quick gains can also be made by connecting older machines to the internet , using connected sensors . This can connect to a controller , which collects data and converts it to a usable format , such as OPC-UA , so the information can be made available to the rest of the factory network .
Businesses have been quick to tap into this trend , with organisations like Bosch , SKF and Festo all offering retrofitting solutions to increase the connectivity of legacy equipment .
To reap the benefits , companies need to determine what influences product quality , downtime and efficiency . They can then retrofit sensors to measure and communicate the information to higher level systems , teaching old equipment new tricks .
About EU Automation :
EU Automation stocks and sells new , used , refurbished and obsolete industrial automation spares . Its global network of preferred partner warehouses , and wholly owned distribution centers , enables it to offer a unique service within the automation industry , spanning the entire globe . It provides worldwide express delivery on all products meaning it can supply any part , to any destination , at very short notice .
www . euautomation . com