Legacy Machine Reconfiguration for Contextual Real-Time Data
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Solution Overview
Problem
Legacy machines in manufacturing environments lack real-time operational data capabilities, and retrofitting them with sensors alone does not provide actionable insights due to lack of context integration with other machines, leading to inefficiencies and risks in upgrading to Industry 4.0 and Smart Manufacturing.
Innovation Solution
A reconfiguration engine and library system that generates instructions for retrofitting legacy machines with IIoT gateway devices, enabling real-time data capture and integration with cloud analytics, using a library of reconfiguration information from various environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If legacy machines are retrofitted with sensors to capture real-time operational data, then data collection capability is improved, but the data lacks context integration with other machines leading to limited actionable insights
Solution Approach 1:
The patent introduces an intermediary system that acts as a mediator between legacy machines and modern analytics platforms. This intermediary captures operational data from legacy machines through sensors and interfaces, then enriches the data with contextual information from other machines and systems in the manufacturing environment. The intermediary handles the complexity of data integration, transformation, and contextualization, allowing legacy machines to provide actionable insights without requiring direct complex integration between all machines.
2Adaptability or versatility
If legacy machines are replaced with modern smart manufacturing equipment, then real-time data capture and connectivity are improved, but capital expenditures and implementation costs increase significantly
Solution Approach 1:
The patent creates a virtual representation or copy of the legacy machine's operational data and characteristics through digital interfaces and data models. Instead of physically replacing the legacy machine with expensive smart equipment, the system creates a digital twin or virtual model that captures the machine's operational parameters and makes them accessible through modern interfaces. This allows the manufacturing system to gain connectivity and data access capabilities while retaining the existing legacy equipment, significantly reducing capital expenditures.
3Productivity
If legacy machines are retrofitted with data capture capabilities, then real-time operational data is obtained, but the retrofitting process becomes complex and time-consuming
Solution Approach 1:
The patent implements preliminary action by pre-configuring standardized interfaces, data collection templates, and integration protocols before the actual retrofitting process. The system prepares data mapping schemas, contextual information structures, and analytics pipelines in advance. When legacy machines are retrofitted, these pre-prepared components can be quickly deployed and configured, significantly reducing the retrofitting time and accelerating the deployment of real-time operational data capabilities across multiple machines.
Data Source
AI summary
Methods and systems are provided for generating reconfiguration instructions for reconfiguring at least one legacy machine in accordance with a reconfiguration event. The method includes employing a computer and/or a user to identify a manufacturing or assembly environment having the at least one legacy machine requiring reconfiguration for generation of real-time operational data and reporting capabilities, the reporting capabilities including collection and processing of a real-time data stream derived from operation of the at one legacy machine during a manufacturing or assembly process operational within the manufacturing or assembly environment, the manufacturing or assembly process producing at least one product; employing at least one of the computer and the user to collect information associated with the at least one legacy machine, the manufacturing or assembly environment, and the manufacturing or assembly process; and employing at least one of a reconfiguration engine and the user to generate the reconfiguration instructions.