Introduction: The integration of legacy machines into modern Industry 4.0 environments remains a significant challenge due to the lack of embedded communication capabilities. Many industrial assets operate without the ability to provide real-time electrical data, limiting their inclusion in digitalized ecosystems.
Methods: This study proposes a monitoring strategy based on the Reference Architectural Model for Industry 4.0 (RAMI 4.0) framework to enable the acquisition and historical recording of electrical parameters from non-connected machines. An IoT-based solution was implemented using an ESP32 microcontroller and an ADE9000 energy metering integrated circuit to measure key electrical parameters, including voltage, current, active power, and energy consumption. Data were transmitted through wireless communication and structured according to Asset Administration Shell (AAS) principles for interoperability and digital representation.
Results: The implementation resulted in a functional digital twin capable of providing real-time monitoring of electrical parameters and storing historical data. The system successfully integrated a previously isolated asset into a connected industrial environment, ensuring compliance with Industry 4.0 standards.
Conclusions: This work demonstrates a standardized and scalable strategy for monitoring and digitizing legacy equipment. The approach enables efficient data collection, historical analysis, and enhanced decision-making, contributing to predictive maintenance and energy optimization. It offers a practical solution for bridging the gap between outdated industrial assets and modern digital ecosystems.