Introducing Copilot BC: the Backwards-Compatible HMI that moves you forward
There’s something almost noble about machines that keep running for decades. They’ve been through it all (shift after shift, line change after line change) and they still get the job done. But no matter how reliable a machine is, it still depends on one vital element to operate smoothly: the Human-Machine Interface. When those interfaces reach the end of their lifecycle and the original models are no longer available, companies face a difficult choice. Do they redesign the entire machine, or find a way to restore its functionality without disrupting everything around it? Copilot BC by System Electronics was developed precisely for these situations. Making legacy machines work within modern systems In most industrial plants, new machines and legacy systems coexist. And while the older machines still do their job, they often struggle to communicate with modern architectures (centralized data systems, updated PLCs, networked supervision, or remote diagnostics platforms). This gap creates friction: it limits visibility, complicates integration, and in some cases, forces operators to manage two parallel systems. Copilot BC addresses this by doing more than just replicating the old interface. When needed, it can be configured to serve as a bridge between outdated hardware and newer plant infrastructures. In one real-world case, a customer needed an HMI for an older machine, but also required that same unit to send production data to a recently installed MES. System Electronics engineered a solution that maintained the legacy protocols for local machine control, while enabling modern communication on the backend. This hybrid approach unlocked data integration without touching the core machine. That’s where backward compatibility becomes strategic. Tailor-made interfaces, not standard panels Copilot BC isn’t a product you order off a shelf. It’s developed case by case, based on what your machine (and your plant) actually requires. That starts with mechanical dimensions, which are often no longer aligned with today’s standard formats. Then come the interface components: do you need a touchscreen, physical buttons, or a combination? Do you want to match the visual layout of the previous panel, or use this as an opportunity to refresh the user experience? System Electronics works closely with each customer to define these elements. If you’re an OEM, you may need an interface that’s not only functional but also branded and harmonized with the rest of your equipment. If you’re managing a plant, you likely want continuity, for operators, for spare part logistics, and for documentation. In both cases, Copilot BC gives you the freedom to build exactly what you need, without compromising on compatibility. Even legacy HMIs running on discontinued operating systems can be supported through dedicated hardware and firmware customization. We ensure mechanical compatibility as well, including rare or obsolete connector layouts. Giving machines a second life without added complexity It’s easy to see Copilot BC as a response to obsolescence, but it’s more accurate to see it as a way to prolong the value of what already works. Many machines are still mechanically sound and operationally efficient. The only thing standing in the way of their continued use is an HMI that can no longer be sourced or serviced. Instead of forcing a complete overhaul, Copilot BC allows you to intervene only where needed. That means lower costs, less downtime, and no need to retrain your team. Your machine keeps doing what it’s designed to do, only now with a modern, supported, and maintainable interface in place. In a moment where extending asset life is economically wise and environmentally responsible, Copilot BC offers a pragmatic and sustainable path forward. A structured development process, built around you Behind every Copilot BC is a proven, methodical process led by System Electronics. It starts with a technical deep dive into your existing HMI: how it connects, how it behaves, how it’s mounted, and how it interacts with the rest of your system. That understanding becomes the foundation of the custom design. From there, our engineering teams move into co-design and prototyping. We replicate the functional logic, reengineer the mechanical layout to fit perfectly into your machine, and develop the necessary firmware to run your legacy software. Special care is taken to support older operating systems, including DOS, and outdated communication protocols, all without compromising performance or stability. We offer full-cycle support in hardware, firmware, and software development. This includes technology conception, prototyping, functional analysis, manufacturing and assembly concept, Design-FMEA, and supplier research for mechanical and electronic parts. Each project is supported by a dedicated project management team, responsible for tracking execution, monitoring timelines and budgets, coordinating internal and external stakeholders, and managing handover from design to series production, ensuring full alignment throughout the lifecycle. In parallel, we manage pre-compliance procedures for electromagnetic compatibility (EMC), such as emitted interference and immunity tests, and handle regulatory approval processes including CE, UL, RED, IEC, and FCC certifications. Once the prototype is validated and approved, the unit is manufactured and delivered ready for long-term use in your industrial environment: robust, certified, and future-ready. And after installation, we remain your partner. Whether you need a software update, an adaptation for another machine, or help scaling the solution across a fleet, support continues well beyond delivery. Now available: Copilot BC by System Electronics Copilot BC is now officially available across industries. As part of System Electronics’ flagship Copilot family, it embodies our commitment to high-end, hyper-personalized solutions. With the guiding motto “Tailormade Electronics to win“, our approach enables even the most challenging customizations, while reducing costs and time to market. It’s already been used to solve problems in real plants, across multiple use cases, and it’s ready to be adapted to yours. Whether you’re an OEM looking to extend the usability of your machines, or a manufacturer trying to maintain operational continuity, Copilot BC offers the flexibility, performance, and customization you need. Talk to System Electronics today and start designing your tailor-made Copilot BC solution.
Meet System Electronics at SPS Parma
From May 13 to 15 Parma (IT) will host the 15th edition of SPS – Smart Production Solutions, the premiere Italian event dedicated to the digital, intelligent and sustainable industry of tomorrow. Join System Electronics on booth E026, hall 5 to discover our latest advancements in the fields of custom devices and automation, HMI copilots and Electronic Manufacturing Services (EMS) and Artifical Intelligence. At System Electronics, we specialize in customized electronic solutions and fully tailored systems built to match your exact needs. By working closely with your team, we deliver technology that streamlines processes, boosts productivity, and keeps you ahead in a fast-moving market. With our expertise and commitment to customization, you don’t just get a supplier, you gain a strategic partner. Under the spotlight at SPS Discover the new HMI concept set to make your life simpler: Copilot BC is the new Copilot by System Electronics especially made for Backwards Compatibility. Good equipment lasts, but HMIs keep evolving faster. With the Copilot BC concept, System Electronics provides you with a tailored HMI compatible with your long-lasting systems and ready to embrace future upgrades. Be the first to experience CoreXpress M, our advanced industrial PC from the CoreXpress family, designed to handle simpler operations with a trusted and flexible technology! Stop by our booth to discover more about ASTRIAL with Astrial H15, the latest update of our customized computing edge AI solution. Engineered for applications like industrial automation and smart manufacturing, ASTRIAL enhances process efficiency through its powerful AI features. With a focus on customization and scalability, the platform helps organizations improve productivity, cut operational costs, and achieve superior performance in dynamic, real-time environments. Our team is looking forward to meeting you in Parma! Date: May 13-15, 2025 Location: Parma, Italy Booth: Hall 5, booth E026