ESP32-Based Project Connects Vintage Machines to the Cloud

A new project utilizing the ESP32 microcontroller aims to bridge the gap between older industrial machines and modern cloud technology. This innovative solution, known as the Retro-Logger, is designed specifically for retrofitting legacy equipment as part of Industry 4.0 initiatives.

Many machines utilized in workshops, laboratories, and factories predate the advent of the Internet yet continue to operate reliably. These include industrial controllers equipped with RS-232 or Modbus interfaces, still commonplace in CNC milling machines, test stands, laboratory pumps, and reflow ovens. However, the challenge arises when attempting to collect data or communicate with these machines, as they do not natively support cloud connectivity. The Retro-Logger addresses this issue directly.

The core of the Retro-Logger is an ESP32 microcontroller, implemented in the form of a FireBeetle board. It communicates via a UART interface, connecting to machines through RX, TX, VCC, and GND. With some modifications, this setup can also accommodate industrial protocols such as RS-485 and Modbus RTU. Data received from these machines is transmitted in real time to a Firebase Realtime Database via HTTPS. The device can operate in either an open prototyping mode or a production-ready version with activated Secure Boot V2 functionality.

The device features four status LEDs that indicate Wi-Fi connectivity, operational status, data reception, and cloud synchronization, aiding in both debugging and on-site deployment. The hardware is housed in a custom 3D-printed enclosure, designed using CAD software like Fusion 360, making it adaptable for use in tight spaces.

The Retro-Logger is particularly beneficial for users dealing with older yet functional machinery. Whether it's CNC milling machines with serial outputs, antiquated laboratory devices utilizing ASCII protocols, or even custom-built robotic arms featuring RS-232 connections, the Retro-Logger serves to link these machines to the cloud. This capability allows for logging machine states, analyzing production data, and enabling remote monitoring without necessitating modifications to the existing control systems.

Once configured, the Retro-Logger can integrate seamlessly into existing infrastructures and connect with modern web technologies such as MQTT, Firebase, or HTTP APIs. For instance, users can monitor parameters like spindle speed, axis positions, and error messages from a CNC milling machine with an RS-232 interface and transmit this information to a designated network location for further processing or user access.

The firmware of the Retro-Logger can be modified and uploaded through the Arduino IDE or ESP-IDF, with the latter providing complete functionality, including Secure Boot capabilities. Additional resources, including detailed project descriptions and the source code, are available on the project's GitHub page.

For those without industrial machinery to retrofit, the principles of the Retro-Logger can also be applied to update older devices, such as creating a remote control for vintage tape recorders.