The task
Decades-old machines stand next to modern systems – and both are to become part of an integrated data strategy. Investing in new machines is often not cost-effective as long as the existing ones continue to work reliably. The aim is to equip existing machines with sensor technology and data acquisition without costly conversions or interruptions to production – and to integrate them seamlessly into the plant’s digital infrastructure.
The challenge
Older machines often have no or only proprietary digital interfaces. They speak fieldbus protocols such as PROFIBUS, PROFINET or Modbus RTU – or no standardized language at all. At the same time, production can hardly be interrupted for lengthy installation work. Retrofit solutions must therefore be non-invasive, quick to install and flexible to use – without interfering with the existing machine control system.
The solution
This is exactly where EdgeBrain comes in. Sensors are connected via an IO-Link master as a hardware bridge – without interfering with the machine control system. IO-Link is a standardized point-to-point connection (IEC 61131-9) that can be combined with almost any generation of machine.
Sensors such as vibration meters, temperature sensors or pressure sensors can be attached directly to motors, pumps or bearings in just a few minutes thanks to their compact design and magnetic holder – without drilling or complex cabling. The IO-Link master transmits the measurement data to EdgeBrain in real time.
EdgeBrain receives all data streams – from IO-Link masters, existing fieldbus loggers and TCP/IP-capable devices – and consolidates them locally. Evaluation, alarming and forwarding take place directly on site, without any cloud connection.
Key technical data
| Parameter |
Value |
| Sensor connection |
IO-Link (IEC 61131-9) |
| Sensor holder |
Magnetic holder, clampable or screwable |
| Protocols |
IO-Link, OPC UA, MQTT, Modbus/TCP |
| Installation time |
< 30 minutes per machine |
| Data processing |
Local on EdgeBrain, real-time |
The added value
The retrofit solution with EdgeBrain makes it possible to integrate older machines into a modern data infrastructure without interrupting production. Operators receive real-time insights into machine status, vibration behaviour and operating parameters – the basis for predictive maintenance and better capacity utilization decisions.
The investment is minimal: instead of a new machine, all you need is an EdgeBrain, an IO-Link master and a few suitable sensors. The result is a digitally networked machine park – from the existing stock, without production downtime.
