Upgrading Legacy Automation Equipment to Achieve Industry 4.0 Compatibility

The development of the Industry 4.0 concept has led to a significant gap between the equipment already existing in industrial plants and current technological standards. This gap can adversely affect efficiency and productivity, requiring significant investment in upgrading equipment to keep pace with new technologies. This paper proposes a solution to reduce this gap and at the same time improve the performance of old equipment by integrating a web server into the PLC structure and using I/O-Link devices. This solution aims to transform old equipment into intelligent devices capable of adapting to environmental and production changes without requiring a complete system reconfiguration, which may be a more cost-effective and feasible option than complete replacement. Through the integration of smart features, the upgrade of older equipment to comply with Industry 4.0 standards allows for adaptive functionality without the need for extensive reconfiguration. This transformation facilitates smooth data exchange, real-time monitoring, and augments operational efficiency, productivity, and flexibility.