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.
Highlights
Manufacturing process information sent to notify user anywhere and anytime in wired and wireless environment to enable the controlling and monitoring between machines and mobile device is the trend in industry [1]
Many small- and medium-sized factories have a large amount of legacy machines, these factories cannot afford advance communication device to implement data acquisition (DAQ) and internetconnection in those machines
The Embedded Smart Box (ESB) architecture this paper proposed is as Fig
Summary
Manufacturing process information sent to notify user anywhere and anytime in wired and wireless environment to enable the controlling and monitoring between machines and mobile device is the trend in industry [1]. The basic design for upgrading machine into I4.0 is building the data acquisition (DAQ) system to collect and store machine-related information. Many machines in manufacturing sites with average lifetimes exceeding twenty years and serviceable are called “legacy” equipment They are incompatible with networks connection and are still being used. How to improve such legacy machines to make them approaching IoT and being compatible presents big problems. For building status sensing and web-connecting ability in legacy machine, this paper focus on building cost-effective Webbased monitoring embedded system to improve legacy machine digitalization and internet connection function.
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