Overcoming Challenges in Integrating Legacy Devices with Asset Administration Shells - An OPC UA Case Study

The transition towards Industry 4.0 requires the modernisation of legacy systems. However, this transformation introduces complexity, mainly due to the variety of data formats and interfaces resulting from the heterogeneity of the used components. For seamless interoperability in Industry 4.0 applications, a harmonised data base is of vital importance. The Asset Administration Shell (AAS), as a standardised digital twin of assets, plays a key role in facilitating interoperable, data-centric solutions in the Industry 4.0 landscape. The prospect of automated data integration offers the potential to reduce errors and optimise the process of digitising legacy systems. This raises the question of what extensions and components within the AAS infrastructure are necessary to realise such automation. In response, this paper presents an architectural concept for integrating legacy systems into the AAS framework. Using an articulated robot as a tangible example, the process of interconnecting data points via the OPC UA protocol is illustrated. Additionally, a prototype is presented, capable of enabling vertical data integration via the BaSyx DataBridge, thus showcasing the notable advantages of automating the incorporation of legacy devices into the AAS. The shown solution retains flexibility and is readily applicable to a variety of systems and scenarios as required.