By allowing these machines to operate "blindly," factories miss out on opportunities to:
Increase overall production efficiency (OEE)
Perform predictive maintenance
Make business decisions with accurate data
The question is, how do you connect old CNCs to the IIoT without replacing valuable machinery? The answer lies in using an IIoT solution specifically for old machinery.
🚧 The main challenge of Data Collection is that machines do not have network ports.
Connecting older CNCs to the IIoT isn't as easy as with new machines. Key challenges include:
Protocol Compatibility: Older CNC machines may use serial ports (e.g. RS-232, RS-485) or brand-specific protocols (e.g. Fanuc FOCAS, Siemens Sinumerik) that modern cloud systems cannot directly read.
Lack of network ports: Lack of Ethernet or Wi-Fi ports prevents data from being sent to IT systems or the cloud.
Data Access: Critical machine status information (e.g., operating status, alarms) is often in the form of basic electrical signals or is difficult to access.
🔑 Key Solutions and Devices: IIoT Gateway CNC Legacy is the "bridge" 🔌
The heart of legacy machine data collection is the IIoT Gateway , or legacy machine data storage device, which acts as a "bridge" to transfer data from the operational (OT) level to the IT (IT/Cloud) level.
1. IIoT Gateway or Industrial PC (IPC)
This device is a key component in an IIoT solution for legacy machinery, playing a key role in:
Legacy port support: Connect to legacy machines via ports such as RS-232, RS-485, or digital/analog I/O.
CNC Protocol Converter: Converts legacy protocols and basic electrical signals into standard , easy-to-understand IIoT protocols such as MQTT or OPC UA before sending the data to the Cloud or Server.
Edge Computing: Data can be filtered, formatted, or partially processed before transmission to reduce the transmission load.
2. External Sensors and Accessories
In cases where older machines cannot transmit data through the port at all, external sensors connected to the IIoT Gateway are required to indirectly collect status data :
Current Clamp Sensor: Measures the current flowing into the machine to determine the operating status (e.g., on/idle/off).
Vibration Sensor: Installed on the machine to monitor the condition of the machine , especially for Predictive Maintenance.
Light Tower Sensor/Indicator: A device that reads light signals directly from the machine's stack light to indicate its status (e.g., working, waiting, trouble).
✅ Steps for implementing Smart Factory for old machinery
To retrofit old machinery into a Smart Factory, you can follow these steps:
Assess and identify data collection points: Review and list what data each old CNC machine can extract (e.g., I/O signals, serial ports, or if current/vibration measurements are required).
Install IIoT Gateway/Data Collector: Select and install legacy machine data storage devices with appropriate ports and protocol conversion features.
Install additional sensors (if necessary): Install external sensors to collect data that cannot be transmitted directly by the machine.
Convert and transmit data (Protocol Conversion): Configure the IIoT Gateway to convert raw data from serial ports or electrical signals into IIoT protocols (such as MQTT) and send it to the IIoT Platform.
Visualization and Analysis: Connect received data to the Dashboard to display OEE , machine status and real-time alerts.
💰 Summary: Overcoming the Limits of Legacy Machine
Connecting legacy CNCs to the IIoT doesn't mean throwing away valuable old machinery, but rather extending the lifespan and improving the performance of existing assets to the level of new machines. With the right IIoT solution and investing in an IIoT Gateway that acts as a CNC protocol converter, your factory can quickly and cost-effectively overcome the limitations of legacy machines and create a Smart Factory. This is a crucial step in increasing competitiveness in the digital age.
| Core technology | IIoT, SmartFactory, Industry4.0, IoTGateway, DataCollection |
| Technical terms | CNC Legacy, Old Machinery, Data Collection, Predictive Maintenance, OEE |
| Solution/Device | IIoTGatewayCNC, protocol converter, RS232, MQTT, OPCUA |
| Thai language only | Smart factory, old CNC connection, IIoT solution, portless machinery |
| industry | Manufacturing, Automation, Factory |
Figure 1: Legacy CNC Problem
This image shows an old CNC machine in operation, but with a disconnected data path or a symbol indicating a disconnection from the cloud or data center.
Figure 2: The IIoT Gateway as the Bridge
This figure shows the IIoT Gateway as the central device connecting an old CNC machine (represented by an old port such as RS-232, I/O) to the cloud/Smart Factory (represented by a Wi-Fi or Ethernet symbol).
Figure 3: External Sensors for Data
This figure shows examples of external sensors attached to older CNC machines, such as Current Clamp Sensors, Vibration Sensors, and Light Tower Sensors.
Figure 4: A Data-Driven Smart Factory
This final image shows an overview of a Smart Factory with a dashboard showing OEE data, real-time machine status, and other benefits of connecting legacy machines to the IIoT.
