Data acquisition


WHEN DATA TRULY WORKS TOGETHER Why standardised interfaces now determine the performance of production systems.


T


he digitalisation of industrial processes is no longer the challenge – their integration is. The decisive difference today no longer lies in additional sensor technology or automation, but in the quality of integration. Production systems only realise their full potential when data is available consistently, in a structured manner and in real time. This is precisely where the real challenge of modern production environments lie: established plant landscapes with different manufacturers, proprietary interfaces and heterogeneous data models. The bottleneck is no longer data acquisition – but its consistent use.


OPC UA AS THE COMMON LANGUAGE OF INDUSTRY


To manage this complexity, standardised communication structures are needed that connect systems in a way that is mutually understandable. This is precisely where OPC UA (Open Platform Communications Unified Architecture) comes in: an open industry standard that enables machines and software to exchange data independently of the platform – in such a way that it is not only transmitted but can also be unambiguously interpreted and processed.


What makes it special is that OPC UA not only provides the description of individual measured values, but also provides contextual information. A system therefore recognises not only what is being sent, but also what it means. This transforms pure data transmission into genuine, interoperable communication – an essential prerequisite for automated processes and data-driven decisions. “The decisive added value arises when data is not only available but is clearly understood within the entire system context – this is precisely what OPC UA was developed for,” says Nils Hubrich, product manager at Minebea Intec, a leading global manufacturer of weighing and inspection technologies. This approach is further refined through so-called Companion Specifications. They define industry-specific data models and ensure that different devices and systems use the same structures and terminology.


STANDARDISATION IN WEIGHING AND INSPECTION PROCESSES


It is particularly in data-intensive sub-processes such as weighing and inspection technology where the importance of this standardisation becomes clear. Here, high material value densities, strict quality requirements and direct impacts on costs and process efficiency converge.


Whether it is the precise weighing of raw materials, recipe control or quality assurance: critical process data is continuously generated here, which must be seamlessly integrated into higher-level systems – because even the smallest


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deviations can have an immediate impact on product quality, material usage and regulatory compliance. “In weighing technology, minimal deviations often determine quality, costs and compliance – which is why it is so important that this data is available consistently and without media breaks,” says Hubrich.


The VDMA Guideline 40200 specifically applies the OPC UA concept to weighing technology. It defines standardised data models and variable structures, so that, for example, a load cell or a control system can be consistently integrated into existing production architectures regardless of the manufacturer. The result: integration becomes predictable. Individual interface programming and time-consuming adaptations are significantly reduced – and production systems gain in transparency, flexibility and future-proofing.


FROM MEASURING POINT TO INTEGRATED DATA NODE


This development fundamentally changes the role of traditional components. Weighing electronics should now be viewed less as isolated measuring systems and more as an integral part of end-to-end data architectures. Modern weight indicators not only record weights but also present measured values, status information, diagnostic data and process parameters available digitally in a structured form – in real time and usable across systems. In doing so, they assume a central role in production control: they provide the data basis for traceability, quality assurance, formulation processes and efficiency analyses. Current solutions such as the MiNexx weight indicators from Minebea Intec are designed precisely to meet these requirements. They combine highly accurate measurement data acquisition with end-to-end, standards-based communication, making data directly usable without additional gateways or proprietary adaptations. They act as an intelligent interface between the field and control levels. In addition to classic industrial protocols, they support OPC UA, integrated web server functionalities and ethernet-based communication as standard, thereby enabling direct connection to MES, ERP or cloud systems. Another crucial aspect in this context is the issue of cyber security. As connectivity increases, so does the importance of secure communication structures. Modern weight indicators take this into account by utilising encrypted data transmission, clear authentication and role models, and secure communication protocols.


This ensures that, particularly in sensitive production environments, data is not only available but also protected and trustworthy. “As connectivity increases, so does the responsibility to protect data reliably – which is


why cyber security must now be an integral part of every industrial communication solution,” says Hubrich. “This turns weight indicators into active, secure data nodes within the production network – and no longer merely providers of individual measurement values.”


INTEGRATION AS AN ECONOMIC FACTOR The economic significance of standardised interfaces is often underestimated. In many projects, a significant proportion of the effort is spent on system integration – not on their actual function.


Particularly in complex plant projects, integration capability is increasingly important for project durations, cost structures and the future expandability of production systems.


Standardised communication significantly reduces this complexity: systems can be commissioned more quickly, expanded more easily and operated more flexibly in the long term. At the same time, data availability improves along the entire value chain – from raw material intake through to production and delivery. This is particularly evident in processes where weighing technology plays a central role: measurement data is integrated directly into control, quality or ERP systems, thereby enabling end-to-end process control in real time.


THE NEXT STEP: UNDERSTANDING DATA RATHER THAN JUST TRANSMITTING IT Industrial networking has entered a new phase. It is no longer a question of whether systems can communicate, but how efficiently and unambiguously they do so. Standardised interfaces such as OPC UA ensure that data is not only available, but also contextualised and interpretable. Only this creates the basis for advanced applications – from automated decisions to data-driven optimisations. Or to put it another way: the performance of modern production is no longer shown by individual machines – but by the quality of the data flows that connect them.


Minebea Intec www.minebea-intec.com September 2026 Instrumentation Monthly


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