Digital services are becoming part of machine building
Digital services are no longer a future trend. They are becoming part of what machine builders and system integrators offer. Manufacturers are under constant pressure to raise machine efficiency, reduce downtime and lower operating costs, and for that they need reliable data from their machines.
Machine data helps OEMs find performance improvements and understand how their machines behave in the field. This is especially valuable during the warranty period, when service incidents drive up support costs. But the value goes well beyond commissioning and warranty: used well, machine data supports the whole machine lifecycle.
More than maintenance: a chance for customer retention
Machine data does more than improve machine quality. OEMs can also use digital services to strengthen customer relationships.
With ongoing visibility into machine performance, machine builders can offer services that continue long after the warranty has ended. Such services help customers get more out of their machines and make long‑term loyalty and repeat business more likely.
As manufacturers digitalize, expectations change. Many now expect digital capabilities not only on new machines, but also on equipment that is already in operation.
The challenge of existing machines
On new machines, digital services are often straightforward, because connectivity and software can be planned from the start. Existing machines are harder.
Changes to the machine control software can be costly, time‑consuming and risky. Sometimes they are not possible at all, because of hardware limits, older control systems or operational constraints.
Technology is another hurdle. Many solutions require tools, platforms or programming environments outside the experience of machine programmers and service technicians. That adds implementation effort, training and project risk.
One approach for new and existing machines
DDAS libraries can run directly in a CODESYS®‑based machine control, so machine programmers stay in their familiar development environment. Alternatively, they run on a separate CODESYS‑based controller or edge device. If the machine control is CODESYS‑based, this is the same engineering environment; otherwise the machine only provides its data, and the separate device is the one CODESYS system.
Teams that already work with CODESYS adopt digital services without learning new technologies or development workflows. The approach builds on the skills machine programmers and service staff already have.
Little impact on the existing machine control
On a separate device, the requirements for the machine control are small. Usually it only has to provide its data through an interface such as OPC UA and a small set of data points, which most modern machines already offer. Other interfaces are possible on request, and for machines without a suitable interface we work out an implementation concept with you as a project.
Why a separate device can be the better choice
Running the libraries on a separate controller or edge device has several advantages:
- software updates without touching the machine control
- one consistent data basis for your HMI or dashboard, across machines
- the same approach for new and installed machines
- independence from the manufacturer of the machine control, as long as the machine provides its data through a supported interface
- space for long‑term data storage that you set up and control
This lets OEMs standardize their digital services across machine generations and controller vendors.
The cost perspective
A separate device adds costs of its own, for example:
- the controller or edge device
- the CODESYS runtime license for that device
- communication licenses, such as an OPC UA client
The DDAS licensing model keeps the software side simple. Machines you develop and build yourself are covered by the company‑wide OEM license: licensed once, unlimited machines of your own build, no runtime fees. For a line with machines from other manufacturers, the DDAS Machine Insight Suite SL in the CODESYS® Store licenses the device; the device needs CODESYS licensing, see the requirements in the store.
Conclusion
Digital services are becoming part of the machine builder’s portfolio. They help OEMs improve machine performance and create services across the machine lifecycle. And customers increasingly expect them not only on new equipment, but also on machines already in operation.
DDAS libraries run either in a CODESYS‑based machine control or on a separate controller or edge device. Machine programmers and service teams use familiar PLC technology and engineering environments, which keeps effort, risk and training low. Each release of the libraries comes with an SBOM in CycloneDX and SPDX format and five years of security updates from the release of its feature level. This is input for your own obligations under the Cyber Resilience Act; on a separate device, the runtime and any software you add are part of your own system.
This gives OEMs one approach for new and existing machines, and a solid basis for machine data, performance improvement and lifecycle services.