Analog Retrofit Module for Legacy Machines
Drop-in analog interface module that bridges modern UART-based controllers to 4–20 mA / 0–10 V signals on legacy machines.
- Converted UART controller data into 4–20 mA and 0–10 V industrial signals
- Added an analog setpoint input, analog feedback output, and digital I/O (SSR trigger, stop input)
- Enabled modern controllers to be retrofitted into older machines
- Technologies: UART, 4–20 mA, 0–10 V, digital I/O
Context
Modern heating controllers had to be integrated into older machines that use analog signals instead of modern digital interfaces.
My Role
I developed an analog module as a retrofit kit for high-end industrial controllers. The module connected internal UART data with analog input/output signals and additional digital control lines.
Technical Challenge
The solution had to make modern controller functions usable in older machines. Digital device data had to be translated into classic industrial signals without fundamentally changing the existing machine environment.
Solution
The module converted UART data into 4–20 mA and 0–10 V signals. It also implemented an analog input for setpoint control, an analog output for temperature feedback and digital I/O such as SSR trigger and stop input.
Impact
The project enabled modern controllers to be integrated into older machines and reduced the barrier for retrofitting and product reuse.
Technologies
UART, 4–20 mA, 0–10 V, Digital I/O, ProAlpha
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