Concepts for Retrofitting Industrial Programmable Logic Controllers for Industrie 4.0 Scenarios

Rupprecht, Bernhard; Trunzer, Emanuel; König, Simone; Vogel‐Heuser, Birgit

doi:10.1109/icit46573.2021.9453558

Cited by 5 publications

(16 citation statements)

References 12 publications

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“…Given that this approach does not require any additional hardware, it reduces installation time and hardware maintenance costs. However, this type of solution is only achievable if the PLC has sufficient processing power to apply the protocol transformation tasks without affecting the original control functions [93]. Although this solution involves short downtime for updating, it could be risky if the system does not have a strong computing processor to support control and connectivity.…”

Section: Embedded Streaming Gatewaymentioning

confidence: 99%

“…This approach can be dangerous as it affects the primary functioning of the PLC which controls the system and alterations may result in failure to generate data. Authors like Rupprecht et al [93] consider the addition of PLC code as a significant issue to safety and reliability. Therefore, this modification in PLC code is not explored further in this study.…”

Section: Embedded Streaming Gatewaymentioning

confidence: 99%

“…Regarding the ability to monitor machines remotely, authors like Rupprecht et al [93] argue that data access should be unidirectional and the remote-control systems within the industry should be internally managed. For these reasons, remote-controlled systems are more likely to be accepted.…”

Section: Comparison Of Retrofitting Solutionsmentioning

confidence: 99%

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Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

2022

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Industry 4.0 technologies and digitalised processes are essential for implementing smart manufacturing within vertically and horizontally integrated production environments. These technologies offer new ways to generate revenue from data-driven services and enable predictive maintenance based on real-time data analytics. They also provide autonomous manufacturing scheduling and resource allocation facilitated by cloud computing technologies and the industrial Internet of Things (IoT). Although the fourth industrial revolution has been underway for more than a decade, the manufacturing sector is still grappling with the process of upgrading manufacturing systems and processes to Industry 4.0-conforming technologies and standards. Small and medium enterprises (SMEs) in particular, cannot always afford to replace their legacy systems with state-of-the-art machines but must look for financially viable alternatives. One such alternative is retrofitting, whereby old manufacturing systems are upgraded with sensors and IoT components to integrate them into a digital workflows across an enterprise. Unfortunately, to date, the scope and systematic process of legacy system retrofitting, and integration are not well understood and currently represent a large gap in the literature. In this article, the authors present an in-depth systematic review of case studies and available literature on legacy system retrofitting. A total of 32 papers met the selection criteria and were particularly relevant to the topic. Three digital retrofitting approaches are identified and compared. The results include insights common technologies used in retrofitting, hardware and software components typically required, and suitable communication protocols for establishing interoperability across the enterprise. These form an initial basis for a theoretical decision-making framework and associated retrofitting guide tool to be developed.

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Section: Embedded Streaming Gatewaymentioning

confidence: 99%

Section: Embedded Streaming Gatewaymentioning

confidence: 99%

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Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

2022

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“…Since this approach does not require any additional hardware, it reduces installation time and hardware maintenance costs. However, this type of solution is only achievable if the PLC has sufficient processing power to apply the protocol of transformation tasks without affecting the original control functions [24].…”

Section: Embedded Streaming Gateway Solutionsmentioning

confidence: 99%

“…This approach can be dangerous as it affects the primary functioning of the PLC which controls the system and alterations may result in failure to generate data. Authors like Rupprecht et al [24] consider the addition of PLC code as a significant issue to safety and reliability. Therefore, this modification in PLC code is not explored further in this study.…”

Section: Embedded Streaming Gateway Solutionsmentioning

confidence: 99%

Industry 4.0: A Review of Digital Retrofitting Solutions for Legacy Manufacturing Systems

Alqoud

Schaefer

Milisavljevic-Syed

2022

Advances in Transdisciplinary Engineering

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Industry 4.0 technologies and digitalised processes are essential for implementing smart manufacturing within vertically and horizontally integrated industries. These technologies offer new ways to generate revenue from data-driven services and enable predictive maintenance based on real-time data analytics. Although the fourth industrial revolution has been underway for more than a decade, the manufacturing sector is still grappling with the process of upgrading manufacturing systems and processes to Industry 4.0-conforming technologies and standards. Small and medium enterprises (SMEs) cannot always afford to replace their legacy systems with state-of-the-art machines. One option available in such cases is known as retrofitting, in which manufacturing systems of past generations are upgraded with sensors and IoT components to integrate them into a digital workflow across the enterprise. Unfortunately, the scope and systematic process of legacy system retrofitting and integration are not yet well understood and currently represent a large gap in the literature. In this article, the authors present an in-depth systematic review of case studies and available literature on legacy system retrofitting. A total of 32 papers met our selection criteria and were particularly relevant to our topic. The results identify three digital retrofitting solutions.

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Retrofitting-Based Development of Brownfield Industry 4.0 and Industry 5.0 Solutions

Tran

Ruppert

Eigner³

et al. 2022

IEEE Access

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The ongoing Industry 4.0 is characterized by the connectivity between components in the manufacturing system. For modern machines, the Internet of Things is a built-in function. In contrast, there are legacy machines in deployment functioning without digital communication. The need to connect them became popular to improve overall production efficiency. As building a new smart factory as a greenfield investment is a capital-intensive choice, retrofitting the existing infrastructure with IoT capability is more reasonable than replacing them. However, this so-called brownfield development, or retrofitting, requires specific prerequisites, e.g., digitization status assessment, technical and connectivity development, management requirement, and operational need, representing a significant disadvantage: lack of scalability. In the meantime, Industry 5.0 is under human-centric priority, which poses new challenges to the retrofitted system. Aware of the challenge, this paper provides a systematic overview of brownfield development regarding technical difficulties, supporting technologies, and possible applications for the legacy system. The research scope focuses on available Industry 4.0 advancements but considers preparing for the forthcoming Industry 5.0. The proposed retrofitting project approach can be a guideline for manufacturers to transform their factories into intelligent spaces with minimal cost and effort but still gain the most applicable solution for management needs. The future direction for other research in brownfield development for Industry 5.0 is also discussed.

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Concepts for Retrofitting Industrial Programmable Logic Controllers for Industrie 4.0 Scenarios

Cited by 5 publications

References 12 publications

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

Industry 4.0: A Review of Digital Retrofitting Solutions for Legacy Manufacturing Systems

Retrofitting-Based Development of Brownfield Industry 4.0 and Industry 5.0 Solutions

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