Plug-and-play technology in industrial plants

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  Plug-and-Play Technology in Industrial Plants

By Nick Boughton, Sales Manager, Boulting Technology

While the common belief is that the technology required for Industry 4.0 is expensive, Combine and Conquer Accenture's report found that the combination of technologies such as AR / VR, big data and machine learning can save large companies an average of £ 60,000 per employee. This article explores the growing trend of plug-and-play technologies.

Although Industry 4.0 is far from a new concept that was first minted at the Hanover Fair in 2011, the long lifespan of industrial machinery and the high costs associated with purchasing smart technologies are still unfavorable to manufacturers Internet of Things (IIoT)

A growing trend for many manufacturers looking to make their factory "smarter" and integrate Industry 4.0 technologies such as remote monitoring and predictive maintenance is the introduction of plug-and-play devices. With growing concern about vendor dependence, choosing hardware that is compatible with existing products within a plant is essential to save costs and ensure compatibility.


Plug-and-play devices are a way to maximize compatibility between new products and existing systems.

A plug-and-play device or computer bus has a specification that allows the discovery of a hardware component in a system without physical device configuration or user intervention.

A variety of IoT features is now available with Plug and Play IoT Kits available. A popular example is the use of sensors that enable digital condition monitoring for any type of machine. Direct physical attachment means that they can take measurements such as vibration and temperature to simplify maintenance schedules without compatibility issues.

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Because many manufacturers and developers of industrial automation equipment produce their own equipment to fill this market, engineers may find it difficult to choose the best solution for their plant and application. Because industrial machinery often has a long life, for example, a motor control center can be maintained with proper maintenance for 20 years, many systems face this dilemma every time they decide to buy new equipment.

Universal Systems

True plug-and-play technologies are capable of integrating devices from all manufacturers, eliminating any integration issues and potential issues. They can also provide quality and performance that exactly meets the requirements of the plant.

While the concept of true, open, plug-and-play technologies may sound idealistic to many, it's a growing trend for many manufacturers of industrial automation solutions such as intelligent drives and remote monitoring software.

Experienced systems integrators can help you achieve that best system for the specific requirements and capabilities of a plant recommended. This includes ensuring the integration of plug-and-play out-of-the-box systems while maintaining cyber security and proven processes from the existing system.


As facilities are constantly being modernized and technology evolves, the selection of products, services, software and hardware is becoming increasingly complicated. The retrofitting of existing systems with new sensors and communication software is therefore becoming more and more popular each year as it is often a much cheaper solution. But also in the area of ​​retrofitting, the relaxation of the providers can be a problem.

Choosing a retrofittable plug-and-play technology that requires less complex integration and user training can continue to ensure cyber security through consistent protocols and firewalls]! Function (f, b, e, v, n, t, s)

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