HK.SYSTEMS _ Digital Retrofit

From analog to digital: How HK.SYSTEMS makes machines IoT-ready

Ready for a smart digital future: In recent years, many companies have increasingly turned to new technologies and initiated numerous projects in the field of IoT. In the digital Internet of Things, networked machines, devices, things or everyday objects exchange a multitude of information and data, they communicate with each other, so to speak. HK.SYSTEMS ensures that this networking works and also makes analog, older devices smart and IoT-capable. Because many are already dealing with the topic of IoT – but we as an IoT specialist can also turn this development into reality: From the required sensor technology, data transmission and data analysis to process optimization measures based on them – we offer everything from a single source.

Analog becomes digital – retrofit as a smart sustainability principle

In many business areas, the digitization process has significantly increased technical requirements. For an existing machine, this means that if you want to continue using it in the interests of sustainability and not dispose of it, the existing components are replaced by modern components. This principle, known as “retrofit,” is one of the hottest trends in the areas of digitization and Industry 4.0. Retrofit stands for “turning old into new. Or also “analog becomes digital”.

That’s exactly what we do: Previously analog machines become digital and smart. This makes the plant IoT-ready and fit again for the demands of Industry 4.0 – with impressive positive effects:

  • Longer machine service life
  • Reduced downtime
  • Lower production costs due to higher energy efficiency, productivity and product quality
  • Compliance with legal requirements (emission regulations, safety requirements, etc.)
  • Possibility of valid and fast acquisition of process and machine data for Industry 4.0
  • No lengthy approval procedures
  • No cost-intensive conversions or new buildings

Smart machines: Indispensable basis for digital Industry 4.0

Machines networked via the Internet of Things and data collected in this way form the indispensable basis for successful, efficient digitization of any company. Retrofitting is a cost-effective way of upgrading existing plants with modern sensor and communication technology. For example, they are able to collect and analyze production data.

More background? Ok: Modern sensor technology ensures that machines can measure physical variables such as temperature, power consumption or pressure. These measured values or data are read out and digitally recorded via our IoT gateway ROSI®. An intelligent approach that does not require any intervention in the existing control system of the plant. The networked machines transmit the data via the Internet to special software that analyzes and visualizes the collected values and, depending on requirements, combines them with other production data.

Via a dashboard, the machine statuses can now be checked at any time and from any location – a perfect basis for efficient planning, control and optimization of production processes. That is the indispensable value of IoT! Just one example that every company should know: Valid predictive maintenance can only be realized via reliable key figure forecasting – and this is precisely what is made possible by intelligent automation of production.

A crucial basis for the required digital networking is our IoT hardware platform ROSI®.

ROSI® – The IoT hardware platform for optimal M2M communication

Intelligent, flexible and secure: ROSI® is the HK.SYSTEMS IoT hardware platform for functioning M2M (machine-to-machine) communication. An ideal solution for the fast path from proof of concept to series production: as a ready-to-use, preconfigured IoT gateway system. With all the necessary components that can be flexibly adapted to any individual requirement: Interfaces, sensors, connections, power supply. Via mobile radio as transmission technology, ROSI® also guarantees 100% secure data transmission. There is no need for time-consuming installation of additional hardware on site.

How we make machines fit and smart for Industry 4.0

With the following steps, we make machines smart. And ensure that our customers do not lose touch with the international competition:

As-is and requirements analysis
The first necessary step: analysis of the existing plants and production processes. Which indicators and measured values should be recorded? Are there already installed sensors? At which points does it make sense to retrofit sensors? Which exact technical requirements should be met in this context?
Component selection
Selection of the required retrofit components for new sensors, hardware and software.
Technical retrofitting of the machine: disassembly of the old and installation of the new components, installation of the hardware and software, implementation of the networking of the machines.
Commissioning / data collection / data evaluation
Commissioning of the new components, measurement and digital acquisition of the data. These are then displayed and evaluated visually in the form of dashboards by the installed software and the IoT platform used.
The collected and evaluated data form the basis for concrete measures for production planning, control and optimization. We can also provide support at this point.

By the way, just about any machine can be made smart, no matter how long it has been in operation. This makes retrofitting the ideal introduction to digital Industry 4.0, because one thing is certain: digitally networked production within a smart factory will be the decisive factor that determines the success of many companies in the future.