Modular control solution for maximum flexibility in assembly

Our partner company SPIE ESCAD Austria has developed modular and scalable control software that can be flexibly adapted to various assembly lines, enables cost-effective expansions, and creates a uniform platform for future-proof production.

Challenge and Objective

The customer operated several assembly lines that had been individually designed by a supplier. Even minimal adjustments to the system or software incurred additional costs. The goal was to create control software that is modular, scalable, and flexible.

Each assembly station should be prepared in terms of hardware and software for a defined maximum expansion and be easily parameterizable. In addition, the solution should be usable for different assembly lines and the line length should be variably adjustable – up to a specified maximum expansion. This should create a uniform platform that enables future expansions and changes without complications.

Solution

The implementation was carried out by the control programming department of our partner company SPIE ESCAD Austria. Two external service providers were involved, who realized the connection to the higher-level SCADA system and the MES. The customer’s IT department took over project coordination.

After detailed coordination, the hardware structure of an assembly station, the communication architecture, and a first draft of the visualization were defined. On this basis, a modular PLC program was created that was tailored to the requirements of a workstation. This module was instantiated, linked to the MES system and the driverless transport systems, and tested in communication and process tests in the development system. Subsequently, the periphery of the existing system was connected to the new control system. The old control system remained on site as a backup. The first tests in the production system revealed that the selected control system was not sufficiently powerful. In addition, the existing OPC-UA communication structure led to an overload of the server. The problem was solved by restructuring the data, optimizing access functions, and using a more powerful control system.
Communication with WLAN components also initially caused an increase in the cycle time and led to control system failures. This problem was also solved by using a more powerful control system. During the test phase, software errors were immediately corrected and necessary adjustments were implemented. After a successful test production, the system went into productive operation. Thanks to the flexible architecture, each of the customer’s assembly lines – regardless of size or hardware variants – can now be operated with the same software. This also led to the standardization of sub-systems in further projects.

Benefits

The customer now benefits from a uniform control platform that can be parameterized within the defined system limits. Expansions are possible with little effort thanks to standardization. The standardization of hardware and software simplifies the supply of spare parts, enables maintenance to access the control logic more quickly, and allows operators to work on different lines without training. This increases flexibility, reduces costs and secures the future viability of production.

These strengths of our partner company SPIE ESCAD Austria were utilized

High flexibility in implementation and fast adaptation to individual customer requirements
Well-founded experience in control technology
Ability to develop customized and standardized solutions that combine efficiency, reliability and future viability
Simple company structure for uncomplicated project execution
Dynamic and eager-to-learn team that works close to the market
Solution-oriented approach and determination

I am very satisfied with the project implementation. The customer can now independently make configurations and flexibly adapt his assembly devices depending on the engine type and assembly step. This allows the assembly lines to be optimally aligned with the required capacities at any time.

Michael Mair
Project Management Control Technology
at our partner company
SPIE ESCAD Austria

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