Machine connection and data acquisition in production

Connecting a machine to a Manufacturing Execution System (MES) is a key step in modernizing manufacturing processes. Through this connection, manufacturing data is collected, analyzed, and managed in real-time, resulting in a significant increase in production control and efficiency. The integration enables seamless communication between machines and the MES, which allows production processes to be better monitored and controlled. This results in faster response times to changes, optimized use of resources, and improved quality standards. Connecting a machine to an MES is a fundamental step on the way to the digitalization of manufacturing and the realization of Industry 4.0 principles.

There are a lot of MES on the market. The following is an excerpt of typical MES and their interfaces:

• Siemens SIMATIC IT MES (e.g. OPC UA, MQTT)
• Rockwell FactoryTalk ProductionCentre (e.g. OPC UA, OPC DA, OPC HDA, REST)
• GE Digital Proficy MES (e.g. OPC UA, REST)
• SAP Manufacturing Execution (ME) and Integration (MII) (e.g. OPC UA, OPC DA, HTTP/HTTPS and XML)
• Wonderware MES (e.g. OPC UA, OPC DA, SOAP, REST)
• MPDV Hydra MES (e.g. OPC UA, OPC DA, HTTP/HTTPS, Web-Services)
• Apriso FlexNet (e.g. OPC UA, Web-Services, REST)
• Critical Manufacturing MES (e.g. OPC UA, Web-Services, REST)
• Camstar Enterprise Platform (e.g. OPC UA, Web-Services, REST)

Our services include:

• Analysis and preparation (target definition, required data points)
• Selection of the appropriate protocol/standard (e.g. OPC-UA, MTConnect, ModbusTCP, MQTT or REST)
• Implementation of communication (configure interfaces and data acquisition in machine and MES, raw data transformation, protocol security, data encryption, data integrity)
• Test and validation (technical test, target matching, acceptance)
• Support (training, monitoring, maintenance, customization)

If you need support in selecting or converting a suitable MES, please do not hesitate to contact us. Together with our partners, we can also support you with this issue.

Individual machine connection to your MES: We accompany you from the requirements to the implementation and support. Get in touch with us now:

Connecting a machine to an Enterprise Resource Planning (ERP) system is an important step towards increasing efficiency in companies. Through this integration, production data is seamlessly transferred to the central ERP system, resulting in improved planning, resource management, and reporting. The machine data makes it possible to accurately track production operations, update stock levels in real time and optimize processes. This connection between machines and the ERP system creates a transparent and well-coordinated environment that forms the basis for informed business decisions and efficient production.

Many different ERP systems are used in manufacturing companies. The following is an excerpt of typical ERP systems and their interfaces:

• SAP ERP (e.g. SAP PI/PO, RESTful APIs)
• Microsoft Dynamics 365 (e.g. via Microsoft Power Automate or Microsoft Common Data Service (CDS))
• Infor ERP (e.g. Infor ION or Infor Mongoose)
• Oracle ERP Cloud (e.g. Oracle Integration Cloud Service (ICS), REST, Oracle Data Integrator (ODI)
• Abas ERP (e.g. abas Integration Server (aIS), REST)
• ProAlpha ERP (e.g. REST, Web Services)
• IFS Applications: (e.g. IFS Integration Framework, IFS Connect, IFS IoT Business Connector)
• GUS-OS Suite (e.g. REST, OPC UA)

Our services include:

• Analysis and preparation (target definition, required data points)
• Selection of the appropriate protocol/standard (e.g. OPC-UA, MTConnect, ModbusTCP, MQTT or REST)
• Implementation of communication (configuring interfaces and data acquisition in machine and ERP, raw data transformation, data mapping in ERP, protocol security, data encryption, data integrity)
• Test and validation (technical test, target matching, acceptance)
• Support (training, monitoring, maintenance, customization)

Individual machine connection to an ERP system: We implement what you need! Get in touch with us now:

Connecting a machine to a SCADA (Supervisory Control and Data Acquisition) system is an essential step in monitoring and controlling industrial processes. Through this integration, machine data can be captured, visualized, and analyzed in real time. SCADA systems provide an easy-to-use interface for displaying operational data, alarms, and trends, allowing for quick identification of deviations and problems. Connecting a machine to a SCADA system helps to optimize production processes, monitor energy consumption, increase efficiency, and reduce response time to malfunctions. This leads to better control and execution of manufacturing processes in a networked production environment.

Many different SCADA systems are used in manufacturing companies. The following is an excerpt of typical SCADA systems and their interfaces:

• Wonderware SCADA (InTouch) (e.g. OPC UA, OPC DA, Modbus TCP/RTU, Siemens S7 protocols and MQTT)
• GE Digital iFIX (e.g. OPC UA, OPC DA, Modbus TCP/RTU)
• Siemens WinCC (e.g. OPC UA, OPC DA, Siemens S7 communication and Modbus TCP/RTU)
• Schneider Electric EcoStruxure SCADA Expert (Citect) (e.g. OPC UA, OPC DA, Modbus TCP/RTU and Siemens S7 communication)
• Ignition SCADA (OPC UA, Modbus TCP/RTU, MQTT, REST)
• WinCC OA (Open Architecture) (e.g. OPC UA, Modbus TCP/RTU, SNMP (Simple Network Management Protocol), REST)
• Inductive Automation SCADA (e.g. OPC UA, Modbus TCP/RTU, MQTT, REST)
• Advantech WebAccess/SCADA (e.g. OPC UA, Modbus TCP/RTU, BACnet (Building Automation and Control Networks) und MQTT)
• COPA-DATA zenon (e.g. OPC UA, OPC DA, Modbus TCP/RTU)

Our services include:

• Analysis and preparation (target definition, required data points)
• Selection of the appropriate protocol/standard (e.g. OPC-UA, MTConnect, ModbusTCP, MQTT or REST)
• Implementation of communication (configuring interfaces and data acquisition in machine and ERP, raw data transformation, data mapping in ERP, protocol security, data encryption, data integrity)
• Test and validation (technical test, target matching, acceptance)
• Support (training, monitoring, maintenance, customization)

We support you in integrating your machine into your SCADA system. Our machine connection and data acquisition starts where you need it.

Retrofitting a machine with sensors (e.g. using IO-Link technology) enables effective modernization of production facilities. IO-Link is a standardized communication protocol that enables the bidirectional transmission of data and parameters between sensors and controllers. By integrating IO-Link sensors, existing machines can be equipped with intelligent sensors that provide precise data on conditions, temperatures, pressures or fill levels. This enables improved monitoring, diagnostics and control of production processes. The retrofitting solution increases efficiency, reduces downtime and supports the shift to predictive maintenance, optimizing the overall performance of the machine.

Typical sensors used in retrofit projects:

• Ultrasound
• Inductive
• Capacitive
• Optical (reflection, transmitted light and light barrier sensors)
• Pressure
• Temperature
• Path
• Slope
• Vibration (vibration or accelerometers)

Our services include:

• Requirements analysis, conceptual design and preparation (target definition, required data points, sensor selection, definition of mounting points, checking power supply)
• Assistance with sensor mounting and cabling (according to IO-Link’s technical specifications and communication requirements)
• Configuration and parameterization of IO-Link sensors and IO-Link masters
• Connection to higher-level systems (ERP, MES, SCADA , etc.)
• Test and validation (technical test, target matching, acceptance)
• Support (training, monitoring, maintenance, customization)

We support you in the retrofit of your machine. Our machine connection and data acquisition from concept to implementation to support. Everything from a single source.

Connecting a machine to the cloud is an essential step towards networked and data-driven manufacturing. This integration makes it possible to capture, transmit, and store machine data in the cloud in real-time. By connecting to the cloud, production data can be centralized and accessed from different locations. This opens up opportunities for asset monitoring, performance data analysis, and predictive maintenance.

Do you want to connect an individual machine as a data source to any cloud system? We support you with the following services:

• Requirements analysis, conceptual design and preparation
  • Goal definition
  • Define the data points you need
  • Security concept (e.g. encryption, authentication and authorization of access)
  • Selection of suitable cloud platforms – e.g. Amazon Web Services (AWS), Microsoft Azure, Google Cloud Platform (GCP)
  • Select communication protocols (e.g. MQTT, REST, OPC U.A.)
• Implementation and Implementation
  • Integrate IoT devices
  • Integrate and configure middleware, drivers, and interfaces
  • Connect to the cloud platform
  • Implement data transfer
  • Configuring data processing and analytics in the cloud
• Test and validation (test, target matching, acceptance)
• Support (training, monitoring, maintenance, customization)

We support you in integrating your machines into a cloud instance. Our machine connection and data acquisition is suitable for any of your machines.