In the fast-evolving world of industrial automation, innovation often collides with reality. At KUKA Assembly and Test GmbH, we’re proud to be at the forefront of robotics and smart manufacturing—but like many industrial leaders, we face a critical challenge: how to integrate cutting-edge technologies like XR5.0 into our existing legacy systems.
The Challenge: Bridging Old and New
Legacy systems, like PLCs, robot controllers, and factory IT infrastructure, are essential in manufacturing. They’re reliable, proven, and deeply embedded in daily operations. But they weren’t built with immersive technologies like XR (Extended Reality) or AI in mind.
This creates several challenges:
- Data accessibility: Systems often lack modern APIs or real-time data streaming capabilities
- Interoperability: Integrating XR devices like HoloLens with older control systems requires custom interfaces and middleware.
- Scalability: Architectures may not be the same thus individual approaches are needed to implement XR applications
- Security and compliance: Ensuring secure data exchange between old systems and new XR platforms is non-trivial
XR5.0 brings a suite of human-centric, AI-powered tools that are designed to work with existing systems—not replace them. Here’s how it helps KUKA overcome integration barriers:
- Digital Twin Layering: XR5.0 enables the creation of digital twins that mirror kinematic behavior using signals from PLCs via OPC UA. This allows real-time visualization of machine states in XR environments without altering the underlying system.
- Modular Architecture: The XR5.0 platform supports modular integration, meaning we can selectively connect XR interfaces to specific parts of our legacy infrastructure—starting small and scaling up.
- Generative AI for Simulation: By generating virtual models of product variants and machine configurations, XR5.0 allows us to simulate and test scenarios without disrupting live systems
- Reduced reliance on physical test parts through virtual commissioning
- Faster troubleshooting via real-time fault detection and XR-guided diagnostics
- Improved training outcomes with immersive, personalized learning experiences
Looking Ahead
Integrating XR5.0 with legacy systems isn’t just a technical upgrade, it’s a strategic move toward a more agile, sustainable, and human-centric manufacturing future. At KUKA, we’re excited to continue this journey, proving that innovation doesn’t mean starting from scratch, it means building smarter on what already works.