AC4DC
Next-Gen Shop Floor Connectivity

AC4DC stands for Asset Connectivity for (4) Data Collection. AC4DC is a product of the industrial software division.

Marc Fröschl, Head of Product Management Team at FORCAM ENISCO: “AC4DC is part of the ‘Machine Connectivity Software’ family and is an innovative software solution that seamlessly connects heterogeneous machines and assets on the shop floor. It normalizes and contextualizes data and efficiently makes it available to systems such as MES or AI applications. With its range of functions, AC4DC represents the first step towards digitalization in manufacturing.”

The AC4DC Control Center is a central platform for managing machine connectivity. It offers an intuitive user interface for configuring and controlling connectivity processes. In the Control Center, templates for connecting machines, preprocessing, and publishing data can be created, edited, and managed.

The AC4DC Gateway is the operational component for machine connectivity in AC4DC. It performs the following key tasks:

• Machine connection: Controls the connection to machines and assets on the shop floor.
• Data processing: Captures, normalizes, and contextualizes machine data directly at the point of origin.
• Data transfer: Reliably transfers the processed data to downstream systems such as MES, ERP, or cloud platforms.
• Buffering during connection interruptions: Temporarily stores data to prevent loss in the event of network disruptions.
• Industrial edge capability: The gateway typically runs on an industrial edge device, ensuring real-time processing, low latency, and high data security.

Systems that work with data from digital machine connectivity use the contextualized and preprocessed data read in by AC4DC to optimize various processes in production and beyond:

1. Manufacturing Execution System (MES): Uses machine data to control, monitor, and optimize production processes (e.g., production planning, order tracking, performance analysis).
2. Enterprise Resource Planning (ERP): Integrates machine data for planning and managing resources such as material requirements, inventory, finances, or supply chain management.
3. Supervisory Control and Data Acquisition (SCADA): Uses data from machines to monitor and control systems, especially in automated production environments.
4. Predictive Maintenance Systems: Analyze machine data (e.g., vibration, temperature) to predict maintenance needs and avoid unplanned downtime.
5. Business Intelligence (BI) and Data Analysis Tools: Use pre-processed data for dashboards, reports, and in-depth analyses to identify trends, bottlenecks, or optimization potential.
6. Quality management systems (QMS): Use machine data to monitor product quality, detect deviations, and ensure traceability for audits.
7. Supply chain management systems (SCM): Integrate production data to optimize supply chain processes, e.g., through accurate predictions of production capacities or delivery times.
8. Internet of Things (IoT) platforms: Aggregate and analyze machine data to enable connected applications such as smart factories or digital twins.
9. Artificial intelligence (AI) and machine learning (ML) systems: Use contextualized data for predictive analytics, process optimization, or anomaly detection, e.g., to predict machine failures or optimize production parameters.
10. Customer relationship management (CRM): Integrates production data to better meet customer requirements (e.g., delivery dates, customer-specific products).
11. Energy management systems: Use machine data to analyze and optimize energy consumption, reducing costs and supporting sustainability goals.
12. Logistics and fleet management systems: Use production data to synchronize transport and logistics processes, e.g., through just-in-time deliveries.
13. Compliance and documentation systems: Use data for traceability and documentation to meet regulatory requirements (e.g., ISO, FDA).
14. Cloud platforms (e.g., AWS, Azure, Google Cloud):  
    Store and process machine data for scalable analytics, integrations, or to support big data applications.
15. Augmented reality (AR)/virtual reality (VR) systems: Use machine data for maintenance instructions, training, or visualizations.

Summary by Marc Fröschl, Head of Product Management Team at FORCAM ENISCO: “The data from machine connectivity with AC4DC can be used in a variety of systems, from operational systems such as MES and SCADA to strategic tools such as ERP and BI. They enable the interoperability of industrial systems and thus the end-to-end digitalization and optimization of production and business processes.”

The advantages of using AC4DC for the digital connection of machines in production:

1. Increased efficiency and productivity:  
   • Data import: Data collection from machines enables precise monitoring of production processes, minimizing downtime and optimizing production times.
   • Contextualization/preprocessing: Raw data is converted into usable information, which speeds up decision-making and reduces manual analysis.
   • Publication: Seamless integration with other systems (e.g., ERP, MES) ensures smooth data flow, improving coordination and planning.
2. Cost reduction:
   • Automated data collection and processing reduces the need for manual data entry and minimizes errors, lowering labor costs.
   • Predictive maintenance based on analyzed machine data prevents costly downtime and extends the service life of equipment.
3. Better decision-making:
   • Contextualized data provides in-depth insights into production processes, such as bottlenecks or inefficient workflows, enabling data-driven optimizations.
   • Dashboards and reports help managers make faster and more accurate decisions.
4. Flexibility and scalability:
   • The software enables the connection of different machines and systems, regardless of manufacturer or protocol, which facilitates integration into existing infrastructures.
   • Scalable solutions grow with the company and adapt to new requirements.
5. Quality improvement:
   • Through continuous monitoring and analysis of machine data, quality deviations can be detected and corrected at an early stage, which increases product quality and reduces waste.
6. Transparency and traceability:
   • The continuous flow of data creates transparency across all production steps, which is crucial for audits, compliance, and traceability (e.g., in the event of complaints).
7. Competitive advantage through digitalization:  
   • Digital connectivity provides the basis for Industry 4.0 approaches such as IoT, AI, and big data analytics, making companies more innovative and future-proof.
     Faster responsiveness to market changes through data-driven flexibility.
8. Improved collaboration:  
   • Sharing data with other systems (e.g., supply chain management or CRM) improves collaboration between departments and external partners.

Summary by Marc Fröschl, Head of Product Management Team at FORCAM ENISCO: “AC4DC enables holistic digitization of production. The data obtained with AC4DC helps companies increase efficiency, quality, and competitiveness and optimally equip themselves for the demands of modern industry.”

The advantages of the containerized FORCAM AC4DC solution over a classic client-server solution can be derived from the properties of containerization and the specific features of AC4DC.

1. Higher reliability: 
AC4DC uses container technologies such as microservices and Kubernetes, which enable robust and resilient data provision. In the event of network disruptions, data is buffered so that no data is lost. In addition, cluster technology enables a quick switch to replacement hardware in the event of failures.
2. Increased data security: 
The solution was developed with a focus on cybersecurity. Data can be encrypted close to the machine, which minimizes the attack surface. Authentication mechanisms further improve the security architecture. This is an advantage over traditional client-server systems, which often require more complex security configurations.
3. Simple and centralized connection: AC4DC enables centralized configuration and operation (on-premise or cloud). Machines are connected centrally using standardized templates from a library, which simplifies administration and reduces complexity. In comparison, client-server solutions often require local installations and more complex configuration processes.
4. Rapid scalability: Thanks to containerization, AC4DC can be scaled quickly. This leads to shorter implementation and scaling phases, enabling a faster return on investment. Traditional client-server architectures are often less flexible and require more effort to scale.
5. Flexibility and hardware independence:  AC4DC runs on industrial micro PCs (AC4DC Gateway), IPCs, or cloud systems, which increases flexibility and reduces dependence on specific hardware. Containerized applications are more portable and can be deployed more easily on different systems than traditional client-server solutions, which are often tied to fixed hardware.
6. Efficient use of resources: Containers require fewer resources than virtual machines, which are often used in client-server architectures. This leads to greater efficiency and lower operating costs.
7. Support for modern IT architectures: AC4DC utilizes modern concepts such as microservices, containerization, and Kubernetes, which enable more flexible and robust IT architectures. This is a paradigm shift from the often rigid structure of classic client-server models, which are less agile in responding to change.

Summary by Benjamin Meißner, Product Expert at FORCAM ENISCO: “As a containerized solution, AC4DC offers greater flexibility, scalability, security, and reliability, as well as easier management and faster implementation, while traditional client-server solutions often lag behind in these areas.”

1. Shorter implementation and scaling phases: AC4DC enables fast connection and scaling of machines through standardized templates and central configuration.  
This significantly reduces implementation times, resulting in lower project costs and a faster return on investment (ROI).
2. Lower hardware costs: 
AC4DC runs on cost-effective industrial micro PCs (AC4DC Gateway), IPCs, or cloud systems that require less powerful hardware than traditional server infrastructures. This lowers hardware acquisition and maintenance costs compared to classic client-server systems, which often require expensive servers and extensive IT infrastructure.
3. Reduced operating costs through resource efficiency: AC4DC’s containerized architecture, based on microservices and Kubernetes, is more resource-efficient than virtual machines. This results in lower operating costs, as less energy and computing power are required.
4. Lower maintenance costs: 
AC4DC’s central control and plug-and-play compatibility minimize installation and maintenance effort. Updates and configurations can be performed centrally, reducing labor costs and downtime.
5. Scalability without high additional costs: The architecture of AC4DC enables easy scaling without the need to set up new servers or complex infrastructures. This saves companies investment costs for additional hardware and IT resources.
6. Lower costs through higher reliability: AC4DC offers features such as data buffering and cluster technology that prevent data loss in the event of network disruptions or hardware failure.

Summary by Marc Fröschl, Head of Product Management Team at FORCAM ENISCO: “AC4DC offers monetary benefits through faster implementation, lower hardware and operating costs, reduced maintenance, and flexible scalability. These factors lead to a faster ROI and sustainable cost savings.”

AC4DC is a future-proof solution for digitalization in production because it offers several features and benefits that meet the requirements of modern, digitalized manufacturing environments and remain adaptable in the long term.

1. Flexible and scalable architecture: AC4DC is based on microservices and Kubernetes, which makes the software modular and expandable. This enables easy scaling for both small and global production networks and the integration of new machines or systems, regardless of their age or manufacturer.
2. High compatibility and standardization: 
The software translates data from old machines to high-end systems into a standardized semantic language. The use of current communication protocols and standardized templates reduces the effort required for adaptation and facilitates integration into existing and future systems.
3. Robust and secure data processing: 
AC4DC offers highly available and secure data streams. Data is encrypted close to the machine, minimizing the risk of cyberattacks or industrial espionage. In the event of network disruptions, the software buffers data so that no information is lost (data buffering). Cluster technology also ensures reliability.
4. Central configuration and easy implementation: Centralized control and configuration enable fast and flexible connection of machines. Guided configuration and a user-friendly interface significantly reduce implementation effort. This accelerates rollouts and minimizes installation and maintenance costs, which is particularly advantageous for international factory networks.
5. Adaptation to Industry 4.0 and smart manufacturing: AC4DC was developed to meet the requirements of Industry 4.0 by increasing transparency, efficiency, and flexibility in manufacturing. It provides the data basis for analyses of energy consumption, performance, and quality, enabling data-driven decisions. The solution is designed to keep pace with the growing demands of digital transformation.
6. Award-winning innovation: FORCAM ENISCO was named the winner of the “Allianz Industrie 4.0 Award Baden-Württemberg” for AC4DC in October 2024, underscoring the relevance and innovative strength of the solution.

Summary by Benjamin Meißner, Product Expert at FORCAM ENISCO: “AC4DC is future-proof because it is flexible, scalable, secure, and cost-efficient, works with modern technologies, and can be seamlessly integrated into existing and future systems. It enables companies to make their production more efficient, transparent, and resilient, which keeps them competitive in the long term.”

As a FORCAM ENISCO customer, you can benefit from AC4DC’s innovations in several ways, as AC4DC is a central component for machine data acquisition and networking within MES FLEX.

1. Improved machine connectivity and data quality
2. Faster implementation and scalability
3. Higher reliability
4. Increased cybersecurity
5. Flexibility through microservices and containerization
6. Reduced hardware requirements

Summary: As an MES FLEX customer, you benefit from AC4DC through faster, more secure, and more scalable machine connectivity, which enables transparency, optimized processes, and cost savings.

• Reduction in the number of servers 

  A customer in the automotive industry was able to reduce the number of servers required for machine connectivity by 85%. Quality, availability, meaningfulness, and frequency of data remained completely unchanged.
• Fast and standardized machine connection 

  A standardized template based on the DMG MORI CELOS system was developed for the machine manufacturer DMG MORI. The connection of the first machine was completed in just 15 minutes, and subsequent machines could be connected in less than 10 minutes.
• Fast, standardized connection in the DMG MORI showroom
  In a joint test with AC4DC and DMG Mori’s CELOS system, the first machine was connected in less than 15 minutes. Two more were connected in less than 5 minutes each.

Benjamin Meißner, Product Expert at FORCAM ENISCO: “AC4DC supports a wide range of common protocols for connecting machine controls and assets on the shop floor.” These include:

• RFC1006: Enables communication with numerous Siemens controllers (e.g., S7-PLC).
• OPC UA: Modern standard for secure and interoperable communication.
  Modbus: Widely used for connecting automation devices.

A complete overview of the supported protocols can be found in our documentation.

Benjamin Meißner, Product Expert at FORCAM ENISCO: “AC4DC supports a variety of common protocols for data transfer to consumer systems and cloud systems to enable flexible and secure integration.” These include:

• OPC UA server: Modern standard for secure, interoperable, and platform-independent M2M and cloud communication, ideal for industrial automation.
• MQTT client: Lightweight protocol for IoT and cloud applications, optimized for low-bandwidth data transmission.
• NATS client: High-performance messaging protocol for distributed systems, suitable for scalable and fast data transmission in cloud environments.
• REST: Future support for REST-based interfaces to enable integration with web-based consumer and cloud systems.

A complete overview of supported protocols can be found in our documentation.

AC4DC: Flexible and scalable industrial software for companies of all sizes

• Small and medium-sized enterprises (SMEs): AC4DC offers a cost-efficient solution for digital transformation and enables easy networking of machines on the shop floor.  
This means that SMEs can make their production processes more efficient while saving costs.
• Large manufacturing companies: Companies with multiple locations or complex production processes benefit from global standardization,  
greater efficiency, and faster ROI.  
AC4DC enables these companies to optimize their production processes while reducing operating costs.
• Scalable system: One outstanding advantage of AC4DC is its ability to grow with your company.  
Whether you want to expand your business, tap into new markets, or integrate additional functions, AC4DC adapts flexibly to your individual requirements.  
This ensures continuous and seamless development that supports and optimizes your business processes.

Summary by Benjamin Meißner, Product Expert at FORCAM ENISCO: “AC4DC is the ideal solution for companies of all sizes. Thanks to its scalability, flexibility, and efficiency, AC4DC offers clear added value to both small and large companies.”

AC4DC is designed for scalability and is based on two main components:

Control Center
The Control Center is the central instance for managing machine connectivity and the associated gateways. It offers a modern, user-friendly interface that can be flexibly adapted to different company sizes and requirements.

Gateway
The Gateway is responsible for connecting machines and assets, contextualizing data, and transferring data to consumer and cloud systems. Scaling is achieved via two mechanisms that can be used individually or in combination:

• Scaling through additional gateways: In segmented networks, multiple gateways are deployed on micro PCs or industrial PCs (IPCs), known as industrial EDGE devices, to distribute the load.
• Scaling through instantiation: Within a gateway, multiple instances can be run on powerful hardware clusters to increase processing capacity.

Summary: AC4DC scales through the flexible use of additional gateways for load distribution in networks and through the instantiation of multiple processes on powerful hardware clusters. The Control Center remains the central, customizable management instance for all connected systems.

AC4DC enables rapid rollout through the following functions:

• User-friendly interface: The intuitive Control Center allows for easy configuration and management of machine connections.
• Pre-built libraries: Libraries for machine data acquisition, signal interpretation, and data standardization accelerate the integration of machines and assets.
• Standardized data transfer: Support for common protocols (e.g., OPC UA, MQTT) ensures fast and seamless connection to consumer and cloud systems.
• Modular architecture: The flexible combination of Control Center and gateways enables a step-by-step introduction tailored to your company’s requirements.

Summary: AC4DC supports rapid rollout with a user-friendly interface, pre-built libraries, and support for standardized protocols such as OPC UA and MQTT. Thanks to its modular architecture, AC4DC can be introduced step by step, efficiently and with minimal implementation effort.

AC4DC ensures reliability and high availability through the following mechanisms:

• Distributed architecture: The control center and gateways operate in a decentralized manner, avoiding single points of failure. This enables uninterrupted operation, even in the event of individual component failures.
• Microservice architecture with automated restart: By using containers in a microservice architecture and Kubernetes functions such as self-healing, failed services are automatically restarted to minimize downtime.
• Kubernetes cluster support: Multiple hardware instances are connected to form a Kubernetes cluster, which ensures availability even under high load or hardware failures through load balancing and automatic scaling.

Summary: AC4DC ensures reliability and high availability through a distributed system architecture that avoids single points of failure, as well as a microservice structure with automatic restart of failed services. Integration with Kubernetes clusters also enables load balancing and automatic scaling for stable operation even under high loa

AC4DC implements comprehensive security concepts to protect machine and production data in critical environments:

• Hardware-based security: Thanks to minimal hardware requirements, the AC4DC gateway can be operated on compact micro PCs or industrial PCs (IPCs) and installed directly in the machine’s control cabinet. This minimizes unencrypted communication paths and reduces attack surfaces.
• Role-based access control (RBAC): Modern user management in the Control Center enables granular access to machines, hierarchies, and data, effectively preventing unauthorized access.
• Encrypted communication: Data transfers to consumer and cloud systems are carried out via secure protocols such as OPC UA and MQTT with end-to-end encryption to ensure confidentiality and integrity.
• Minimization of third-party software: AC4DC relies on a lean software architecture with reduced use of third-party components. Regular checks and updates of dependencies minimize security vulnerabilities.

Summary by Marc Fröschl, Head of Product Management Team at FORCAM ENISCO: “AC4DC protects machine and production data through hardware-based installation, encrypted communication, and role-based access control. The lean architecture with minimal use of third-party software and regular security updates also ensure robust protection in critical production environments.”

The architecture of AC4DC is modular and highly flexible to support a wide variety of application scenarios in industrial data processing.

The AC4DC Control Center has a flexible structure and supports various architecture variants.

It can:

• on its own system (IPC/server),
• in a cloud instance, or
• together with a gateway (except for the installation of the gateway on a micro PC)

  It enables the central management of any number of gateways and features a granular rights and roles concept that allows user access to be restricted to specific elements of the system hierarchy. This allows individual and scalable target architectures to be implemented.

The AC4DC gateway supports various installation options, depending on the application and infrastructure:

• Industrial micro PCs: 
Installation directly in the control cabinet of a machine, ideal for decentralized applications. In this scenario, one asset is managed per gateway.
• Single server or IPC: 
Centralized operation with the option of connecting multiple assets per gateway – suitable for machine networks or production areas.
• Kubernetes cluster: 
Highly scalable solution across multiple systems, also with multiple assets per gateway – ideal for large, dynamic environments.

Summary: The target architecture of AC4DC is modular and flexible in order to cover a wide variety of industrial scenarios. This flexible architecture makes it possible to efficiently integrate AC4DC into both lean single applications and large-scale Industry 4.0 landscapes.

General:  
AC4DC is designed for on-premise and private cloud operation.  
AC4DC is also available as a SaaS variant through our cloud partners.

Specific:
AC4DC supports different operating models and can be flexibly integrated into existing IT landscapes – entirely according to the requirements of the respective company.

Control Center operating models:
The AC4DC Control Center can be operated in any of the following operating models:

• On-premise: Installation on company-owned hardware (e.g., IPC or server) within the local network
• Private cloud: Operation in a dedicated cloud environment belonging to the customer
• SaaS model (Software as a Service): Use as a fully managed solution from the cloud.

Gateway operating models:
The AC4DC Gateway can be operated in three models:

• On-premise: Installation on local hardware (micro PC, IPC, or server) in the company network.
• Private cloud: Operation in a dedicated cloud environment belonging to the customer.
• SaaS model: Use as a fully cloud-managed solution on the customer’s own hardware.

For optimal performance and cybersecurity, we recommend on-premise installation as close as possible to the data-collecting assets.

Summary: AC4DC supports flexible operating models and can be seamlessly integrated into existing IT landscapes. Both the control center and the gateways can be operated locally, cloud-based, or as a managed solution, depending on requirements, with on-premise being particularly recommended for high performance and security.

AC4DC is based on the proprietary microservice platform MCC. 
The MCC platform is designed for the orchestration of containerized microservices and optimized for processing complex data streams. 
It offers standardized infrastructure components for microservices, such as license and user management.

APIs for FORCAM ENISCO legacy systems are provided for AC4DC, which also enables our existing customers to benefit from technical advances and innovations. 
benefit from technical advances and innovations.

Data are collected in AC4DC via the AC4DC gateway, which supports a variety of southbound protocols. 
These protocols enable signals to be read directly from the connected assets. This allows, for example, process and operating data to be collected and processed efficiently and reliably.

The AC4DC Gateway offers various northbound protocols for data transfer. In addition, an OPC UA server can be started on each southbound connection, which can also be used to provide data.

Both raw signals and contextualized and semantically enriched data can thus be transmitted to consumer systems. The data payload of northbound communication is flexibly configurable and can be individually adapted to the requirements of the target systems.

The captured signals can be evaluated and semantically enriched directly on the AC4DC gateway. 
To this end, AC4DC provides freely programmable function blocks that allow the raw data to be flexibly processed and contextualized.

These blocks are programmed in Structured Text in accordance with IEC 61131, an established standard for industrial automation.

AC4DC can receive data from higher-level systems. 
This is done via the northbound interfaces in the form of so-called commands or via the integrated OPC UA servers. 
This allows commands or order information from higher-level systems to be transferred to the AC4DC system, for example.

Data received from higher-level systems can be evaluated and further processed in function blocks within the AC4DC gateway. 
This allows, for example, setpoints or order data to be used in a targeted manner.
If the connected controller allows it, this data can also be forwarded directly to the controller and processed there.

Yes, provided that the connected controller supports this, AC4DC can write signals directly to the machine controller. 
This enables, for example, the transfer of setpoints, control commands, or parameters from higher-level systems or function blocks in the gateway.

However, writing data is subject to latency, depending on the network and system load. We do not recommend using this technique for time-critical processes.

The interface is divided into two central areas:

• Asset Management: 
Provides a hierarchical structure of the connected AC4DC gateways and assets. 
All created elements—such as southbound and northbound interfaces—are clearly displayed to enable easy navigation and management.
• Template Management: 
Enables centralized management of all created templates and their components, such as program units, data structures, and other building blocks. 
This facilitates the reuse and standardization of functions within the system.

Summary: The modern user interface of the AC4DC Control Center is intuitively designed and enables quick and easy access to system configuration and management.

Signal processing takes place directly on the AC4DC gateway using so-called function blocks. A wide range of predefined blocks is available for this purpose. In addition, it is possible to create your own functions and blocks in Structured Text according to IEC 61131. This allows individual logic to be implemented flexibly and adapted to specific requirements.

Yes, AC4DC has a granular rights and roles concept. 
User access can be restricted to specific areas of the system hierarchy. This allows roles with specific permissions to be defined to ensure security, traceability, and efficient collaboration.

AC4DC flexibly transmits data to numerous systems thanks to customizable northbound interfaces and an integrated OPC UA server.

AC4DC is fully containerized and optimized for operation in Kubernetes.
This architecture enables flexible, scalable, and efficient deployment.

The container approach makes it easy to automate and standardize updates, rollouts, and maintenance processes.

A Linux-based runtime environment with Kubernetes support is required.
Other requirements, such as CPU and RAM, depend on the specific application and the number of connected assets.

You can find more details in the system requirements.

By using AKS Edge Essentials (AKSEE), a Kubernetes environment can be provided under Windows in which AC4DC can be installed and operated.
However, a native Linux infrastructure is strongly recommended for productive and scalable environments, as it offers greater stability, performance, and better compatibility with containerized applications.