When manufacturers implement MES or OEE systems, the first challenge is often not the software platform. It is connecting existing machines on the shop floor.
Stamping and hydraulic presses may come from different manufacturers and generations. Some have no communication interface, some use PLC programs that are difficult to modify, and others only provide basic signals such as running, fault, and production count.
Modifying every PLC, adding communication modules, or developing custom drivers for each machine can quickly increase project time, cost, and risk.
EdgeIO provides a simpler approach.
Without replacing the original PLC or changing the machine control and safety circuits, EdgeIO can collect data from existing auxiliary contacts, pulse signals, analog inputs, and Modbus devices, including:
• Running, idle, stopped, and fault status
• Stroke count, hydraulic cycle count, and production count
• Motor current, hydraulic pressure, and temperature
• Data from energy meters, variable-frequency drives, and temperature controllers
The collected data can be sent to MES, OEE, SCADA, or industrial data platforms through OPC UA, MQTT, or Modbus TCP.
The original machine remains responsible for control and safety. MES or OEE software handles shift rules, downtime analysis, historical records, and OEE calculations.
This approach is especially useful for factories operating multiple brands and generations of stamping or hydraulic presses.
A system integrator can begin with one representative machine to verify the wiring, data points, and communication method. Once validated, the same configuration can be reused across similar machines and gradually expanded by production line or workshop.
For manufacturers, EdgeIO lowers the entry barrier for connecting legacy equipment and makes machine status and production data automatically available to management systems.
For MES and OEE integrators, it provides a standardized way to combine digital signals, analog inputs, pulse counts, and Modbus data into a consistent machine-connectivity solution.
If legacy stamping or hydraulic presses are creating a data gap in your MES or OEE project, start with one machine and build a repeatable solution from there.
