Extracting data from a legacy plant

You want to bring your legacy plant into the 21st century by implementing comprehensive monitoring and data analysis. But there’s a problem. How do you access the data you need? Tim Dodd of ifm electronic tells all.

If you operate or manage a production plant, there are three things that you almost certainly want to do: predict machine availability, improve process quality, and optimise energy usage.

Most of the data you need probably exists in your plant, but how can you get at it without spending a fortune and upsetting operation? This can be particularly challenging with legacy installations where, for example, sensors may only have a single 4-20mA analogue output.

There are expensive solutions that involve adding many extra sensors or even replacing all the older devices, but these drastic methods may not offer a good return on investment. Fortunately, there are alternatives that are more convenient and cost effective.


Read the full article in DPA's July 2025 issue


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