Embedded smart box for legacy machines to approach to I 4.0 in smart manufacturing

Abstract

Abstract. This paper introduces the design of a Linux-based embedded controller which includes machine state detection application for legacy machines and manufacturing line. For Industrie 4.0 (I4.0), it is important to acquire, manipulate, and transmit machine operating states or physical data to form useful information. However, many existing legacy machines lack of controller or sensor(s) to response to their operating status. Some machine controllers cannot be connected to provide internal parameter(s) by means of communication. Gathering machine operating state should be the first priority to approach to I4.0. This paper adopts widely used Raspberry PI as the core platform to build Embedded Smart Box (ESB). It uses external sensors to detect the machine operating status to compute the machine's availability (one of Overall Equipment Efficiency factors) and measures current to calculate the power consumption. In this research, the combination of embedded system and sensors can be a smart box for legacy machines. Such cost-effective design would help users to take the useful data from the machines and construct the base of I4.0 system even without the existence of the controller. This embedded-based design methodology has great potential implications that might fundamentally change the legacy factories into I4.0 smart one.

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

“…Existing legacy equipment lacks sensors to indicate their operating status [69], thus additional sensors should be integrated. Several researchers stated the difference between a general-purpose sensor and an IoT-specific purpose sensor [70].…”

“…Oil extraction [54] WebSocket Metal cutting [118], CNC machining [115], Metal forming [69] TABLE 7. Advancement in the data layer integrated storage for further processing [39].…”

“…The core of this concept is the kaizen activity, which is done by a group of people to solve an organizational problem [156]. For the retrofitted system, this kind of activity is highly supported due to the availability of data, the visualization of the critical parameters, and the human-centric approach when designing the retrofitting solution [69].…”

“…Aluminium production [37], Fabric knitting [78], Textile [15], Metal casting [125], Gear production [63], Metal forming [69] TABLE 13. The possible advantages of Lean 4.0 in retrofitted system decision-making capability of workers, allowing them to take part in more knowledge tasks in sustainable manufacturing from human factor [87].…”

“…Textile [15], [71], [97], Metal cutting [53], Oil extraction [54], Car assembly [75], Olive oil processing [95], Metal forming [69] Maintenance parameters record…”