An action research study on the digital transformation of concentrated solar thermal plants

The fourth industrial revolution (I4.0) marks the beginning of a new data-based age in which people, machines, products, and facilities are interconnected to realize smart factories. However, in practice many industrial facilities still rely on conventional automation pyramid system infrastructures according to the third industrial revolution (I3.0) paradigm. Particularly concentrated solar thermal (CST) technologies can benefit from the advances of I4.0, which can increase efficiency, flexibility, and productivity while reducing costs. However, the domain is still in its infancy with respect to the digitization and automation of its infrastructure. Comprehensive digital transformation approaches and integrated technical solution strategies are essential to illustrate how current CST facilities can update their operations and leverage I4.0 technologies holistically. To bridge the gap between scientific progress, technological advances, and practical application, this study conducts action research in a CST plant. The goal is to demonstrate the digital transformation of an existing facility into a cyber–physical system according to the principles of I4.0. Thus, the study covers the entire development lifecycle of an I4.0 middleware layer that allows to subsequently retrofit CST plants into smart factories in brownfield scenarios. As a result, we generate theory from practice and generalize the learnings as a blueprint for the digital transformation of solar energy systems and comparable industrial environments. • A CPS infrastructure can increase the level of digitization and automation in plants • A holistic digital I4.0 transformation project can be based on a CPS middleware layer • The middleware layer enables a stepwise and non-disruptive transformation process • IoT ARM can be used as a framework support the infrastructure transformation process • Study results can serve as a practical example for other I4.0 transformation projects