Old But Connected Why the True Data Treasure Lies in the Machinery Inventory

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Weidmüller Interface GmbH & Co. KG

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Digital value creation begins with machine data from the brownfield. Weidmüller demonstrated at its in-house exhibition how existing facilities can be made ready for digital production and energy management with open solutions.

The digitalization of industry thrives on data. Many potentials remain untapped, particularly in mature machinery parks, because older systems are often not designed for systematic data collection – for instance, because they only have outdated interfaces, do not allow sensor integration, or only display data locally instead of providing it centrally.

To become more efficient in the long term and thus remain competitive, one must also ensure transparency in existing systems and make production data usable. The example of Weidmüller shows how, with open architectures and retrofittable solutions, machine data from existing plants can be accessed, analyzed, and specifically used for efficiency enhancement and sustainability. The range extends from modular hardware to flexible control technology to practical software for analysis, visualization, and resource management.

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Entry by Example: Machine Data from Production

Weidmüller demonstrates digitization from its own practice: On an automated assembly line, the so-called Rail Assembler, Weidmüller shows how machine data can be generated and used during operation. The system cuts support rails to size, equips them with terminal blocks, and continuously provides data on position, consumption, and status. This information forms the basis for monitoring, maintenance, and energy optimization — for instance, through peak load management, consumption monitoring, or predictive maintenance strategies. The example shows how individual machines can become the starting point for a comprehensive digital strategy.

Brownfield as the Royal Discipline: Digitalization of Existing Systems

Many machinery fleets consist of systems that have been running reliably for years — mechanically robust but digitally isolated. This is where enormous potential for efficiency gains lies. Weidmüller refers to the "Champions League" scenario: digitization during ongoing operations without disturbing existing controls or processes. Retrofit components, open interfaces, and modular additions also turn older machines into data providers. This way, even long-used systems can be integrated into modern value chains.

From Sensor to Cloud: Components and System Architecture

The technical foundation is formed by modular systems consisting of sensors, controls, and communication. Signal converters separate, convert, and amplify industrial signals. Communicative power supplies can also be integrated retrospectively.

The heart is the I/O-System U-Remote with adaptable architecture and common protocols such as EtherCAT or Profinet. The system is complemented by edge controllers based on Linux, which can be flexibly adapted via apps.

In addition, Weidmüller offers an extensive portfolio of network components, including managed and unmanaged switches and security routers. These ensure secure and reliable data communication within the automation architecture and form the bridge to higher-level IT systems.

This creates an end-to-end connection: Sensors provide raw data, which is processed locally, analyzed by edge controllers, and transmitted over industrial networks to central systems or cloud platforms.

Software for Practice: Data Acquisition, Visualization and Analysis

Without suitable software, any data collection remains ineffective. With Procon Connect, machine data can be quickly read and processed without programming. Procon Web provides role-based visualization: operators, maintenance personnel, and energy managers each see only what is relevant to them. Resma complements data analysis with functions for energy metrics and CO₂ balances, such as the automatic recording of consumption data, calculation of emission values according to Scope 1 and 2, and assignment of these data to production orders. The software components interlock and cover the entire path from acquisition to evaluation.

Engineering and consulting: Support throughout the entire digitalization process Technology alone is not enough; digital transformation needs guidance. Weidmüller offers technical consulting, project planning, and support with regulatory requirements such as sustainability reports or later the Cyber Resilience Act.

Instead of isolated products, Weidmüller delivers seamless solutions, developed in collaboration with the customer. From specifications to implementation to operation, experienced contacts accompany the entire process, resulting in a practical, integrated digital strategy.

Flexibility as a Guiding Principle: Openness in Hardware and Software

Only a few large players can afford a closed, proprietary automation system. Medium-sized companies like Weidmüller, therefore, aim to score with open systems. Industrial PCs with Linux and Docker containers form the backbone of modern industrial architectures. Weidmüller relies on modular components and its own Linux-based operating system (u-OS), which can be individually extended via apps. Users can continue to use existing programming environments or integrate their own applications. This openness reduces dependencies, facilitates retrofitting, and enables manufacturer-independent concepts.

The future of production is data-driven, and this transformation does not start with new machines. Weidmüller demonstrates how existing systems can be digitally retrofitted with manageable effort. Essential for this is a combination of flexible hardware, open software, and targeted consulting. This creates a seamless data flow from the machine to the cloud, supporting both operational efficiency and regulatory requirements. Those who digitize in the brownfield today lay the foundation for resilient, sustainable, and future-proof production. (mc)