The difference between the simulation and the real drive is the acceleration of the drives, which is not mapped in the simulation. With the PTP movement, the real drives are not given a speed value, only a time. This is because the drives are normally moved by the spline movement of the motion control software.

Data processing functions have been implemented in the graphical user interface (GUI) that enable a CSV file and an image to be read in. The CSV file contains all movement commands and can be visualized within the GUI (see Fig. 1). When an image is read in, color filtering takes place first, during which various parameters must be adjusted in order to achieve optimal results. The movement commands are then supplemented using image-processing methods. Once these commands have been generated, a command sequence can be created from the image that enables the image to be plotted.

Less paper, more efficiency

The application, called ‘Montagewebsite’, supports fitters working outside the company on construction sites and at customers’ premises. Using a tablet with a secure VPN connection, daily reports can be created digitally, filled out and saved live in the database. Photos for documentation and digital signatures can easily be added to the report. Project data sheets or article information can also be viewed on site with just a few clicks. Previously, several folders with printed documents had to be carried around and it was not possible to view the database if documents were missing. The time savings and efficiency gained through this digitization are enormous and lead to a significant simplification of the company processes.

On this basis, QA has developed an additional function that enables fitters on site to report defective or missing material. This process automatically generates a notification to the warehouse and a corresponding order proposal.

Using the Microsoft web framework Blazor, a front-end application was created in C# and .Net, which accesses the current Access database of the ERP system QAenterprise. QA successfully set up a modern web application on the existing database and integrated the new data.

Automation in ordering

At Müller & Sohn, part of the purchasing and material orders are processed via an external ordering platform. In order to significantly increase efficiency in the ordering process, QA implemented the following measures to automate the processes: Using an interface, the C# application developed by QA automatically creates projects and cost centers from the ERP system QAenterprise on the external ordering platform. A CSV file is used as the interface. Hourly synchronization ensures that the current project and cost centre list is compared and updated between QAenterprise and the ordering platform.
Once an order has been triggered by Müller & Sohn, the ordering platform generates an XML file that is stored on the in-house FTP server. This file is automatically imported by the new application and the initiated order is created in QAenterprise so that it can be used for project statistics and incoming and outgoing invoices.
QA has also fully automated an e-mail inbox, which is used to handle part of the ordering process. For example, tool certificates or order confirmations are received as PDFs, which are then automatically saved in the internal server’s file system. From there, the data is automatically imported into QAenterprise and assigned to an order or project.

Further automation in the ordering system is currently still in the development phase. A “material list” for Excel is generated from drawings in the design department. This list contains all items required for internal manufacturing and production. QA is now using C# to develop an automated process that imports the Excel list into QAenterprise and automatically creates the associated purchase orders. The import process consists of reading the file and recognizing and processing the contents. In addition to considerable time savings, this also results in fewer errors. For example, the system checks whether an item is a stock item and whether it is still available in sufficient quantities in the warehouse. In the case of an internal stock item, no purchase order is created, but a stock issue is posted with allocation to the project. For certain items that are marked accordingly in the master data, a notification is generated for the purchasing department, as manual price inquiries have to be made with various suppliers beforehand. Scaled prices from the respective suppliers are also taken into account across projects and orders so that cheaper collective orders can be used instead of individual orders. These graduated prices are stored in a configuration in the database.

AI.ready with QA

Thanks to the collaboration between our experts in automation technology and our application development department, we can provide you with decisive competitive advantages through highly professional data mining, taking into account your process expertise and experience. With AI.ready, we work with you to develop a potential analysis from which you can derive the benefits of AI software and also see which steps are required for successful implementation. AI.ready begins with an analysis and review of your existing data. Which data is relevant to the process and where are parameters still missing? It is often possible to derive easily implementable improvement measures at this point.

We can collect missing data either by installing additional sensors or by expanding the machine control system and integrating an OPC UA server and storing it in databases. Using importers specially developed by QA, we implement interfaces between your various data sources and the AI software, or simply put: “We bring your data to the AI.”

But our service doesn’t end there. Of course, you also want to be able to view the data analyzed by AI. The application department at Quality Automation GmbH specializes in precisely this requirement. Monitor all your system parameters using modern web interfaces that display limit values, warnings and push notifications through informative visualizations. On request, we can send the AI decisions directly to the control system to close the fully automated control loop.

Do you already have software or an application that is outdated or no longer offers the desired functionalities? Here too, you can benefit from the knowledge of our experienced software developers. We will analyze your existing software on site and offer you various options for restoring it to a maintainable and modern state.

Project result

The inverter can be controlled as desired via the ctrlX controller. All variables and the FB were documented very precisely for internal purposes. The absolute positioning, relative positioning, speed control and torque control operating modes have been successfully implemented.
In position control, a target position with a ramp profile is approached after the start command. The ramp profile contains acceleration, deceleration and a maximum speed. The setpoint is specified either as an absolute or relative position offset.
With speed control, a set speed with ramp profile is approached after the start command. The ramp profile contains acceleration and deceleration. Torque control can be controlled continuously. The target torque is applied in real time. This allows torque curves to be realized.
In addition, a module was developed to use the servos to drive a linear axis. This FB in turn uses the servo FB. The axis can measure itself during initialization, which means that the axis can be positioned relatively and absolutely and a speed specification is also possible.
In addition, an HMI user interface was created with which the PLC program can be controlled and monitored. This includes various switchable menus, user administration and alarm management with acknowledgement function.

Disassembly in Germany

Together with the customer, the project plan was finalized, the disassembly and subsequent assembly were planned down to the smallest detail. The project plan was tight and time-critical; it was not possible to order additional support or materials at short notice. The QA team accompanied the entire disassembly in Germany, documented it and already made preparations for the upcoming reassembly. Shortly before the start of the journey, the pandemic in China subsided and the strict entry regulations were relaxed. With a negative PCR test, our team now traveled much more relaxed and under less strict conditions. With a stopover in Shanghai, the journey went smoothly and the next day our team was already on site and could start with the first preparations and assessments.

The all-in-one solution: ctrlX CORE

With its open and flexible architecture, the ctrlX CORE industrial controller meets the current and future requirements of the factory of the future. In addition to EtherCAT, the control hardware supports many other common automation protocols. The ctrlX Device Portal enables remote access to the controllers as well as their easy management and updating.

In networked environments, the Ethernet interface handles data-intensive information exchange with higher-level IT systems, HMI devices, and cloud-based applications. The controller supports more than 30 IT and PLC IoT standards such as OPC UA as server and client as well as the widely used MQTT protocol.

Development of a new software solution

Before the digitization realized by Quality Automation GmbH, all CAD drawings had to be printed out so that they could be worked with in the workshop. This resulted in increased costs, time and resources. The goal was to digitize this process and thus make it more effective and modern.

Like QA Enterprise, the digital manufacturing management software is based on Microsoft Access and can be integrated into the ERP system if desired. However, the flexible standalone solution that we have implemented here is by no means disadvantageous and integration is also possible at a later date at any time. The software developed from scratch by Quality Automation GmbH has resulted in a perfect application tailored to the customer’s needs, which can be extended and adapted at any time if required.