Database as automation center
When Huba Control produces sensors, orders with a batch size of between 1 and a thousand parts can be processed without any problems. This is made possible by a plain automation structure with an SQL database at its centre. The SQL4automation Connector ensures fast and reliable communication between the controller and the database.
Huba Control AG, based in Würenlos/Switzerland, develops, manufactures and markets components for measuring the physical quantities pressure and flow. This includes pressure switches, sensors, pressure transmitters as well as flow sensors. "The company successfully produces products in Switzerland for industry and building automation," according to Stefan Keller, head of the controller technology division at Münsingen/Switzerland based INSYS Industriesysteme AG. INSYS constructed the fully automatic production system at Huba, set it up ready-to-use and put it into operation. The system manufactures, labels and checks the sensors with assembly and fusion processes, while ensuring absolute flexibility.
"Everything runs automatically, right up to the finished sensor", Keller adds. In order to be able to perfectly meet the customers' requirements, the annual production volume ranges between one unit and a thousand parts, depending on the product. "Express orders can also be processed quickly, and even be carried out between other processes", the Professional Bachelor ODEC in Informatics Engineering stresses.
Orders directly from the ERP system
"All orders come directly from the ERP system", Keller continues. The AP+ system takes decisions on order processing based also on the condition of the system and the material available in the storage facilities, which the system monitors. The required parts come from the parts storage depot, which is controlled by the ERP system, and are transferred via an assembly feed system. "Almost in real time, the available material is matched with the orders", he adds. This process even takes into consideration that certain casings have been cleaned in the warehouse and thus have to be processed within a certain timeframe. The parts needed to manufacture a certain product are communicated to the ERP system via the link to engineering. "The processing cells are each equipped with their own object-oriented CODESYS 3.5 Soft-SPS", the automation expert continues. Every cell, in turn, consists of different stations. Everything has a highly modular structure.
How does the dynamic production system handle a batch size of 1 and a chaotic manufacturing process?" S. Keller responds: "The heart of the automation architecture is that all required data, like the setting parameters, is stored in the central SQL database and therefore not in the system controller." The complete data communication runs over a database, which is also connected with the ERP database. Only thanks to this constellation, it is possible to very flexibly assemble parts for 40.32 million different sensors (not counting customer specific labelling).
Automating automation
"The controller only knows about the type that needs to be produced at that moment", Keller tells us. "The currently needed particular data set is retrieved by the PLC from the SQL database via the SQL4automation Connector." This means that the controller is completely relived from data handling. "The Connector takes on the effective connection to the MS SQL Server via the ODBC communication channel with a high amount of reliability", Keller stresses. "This opens up new possibilities: A control system with an OPC-server is no longer required." The PLC or the robot control system sends the database request via the Connector itself and is sent back a response in a form which is legible for the controller. The reaction time for such a query ranges between 100 ms and 250 ms, even when dealing with very large amounts of data. These queries only require a small amount of extra work during PLC programming. The SQL4automation Connector only has to be configured. "As a consequence, the entire middle layer and the associated engineering and maintenance effort is replaced", Keller tells us. "Summed up, this results in high improvements in efficiency and is an important step towards automating automation."
"It is basically possible to manufacture a different type every few seconds", he adds. When new parts come into the station on the goods carrier, the ID is read and the controller asks the database what to produce or what to produce first. "The so-called marriage of the order from the ERP system with the parameters from the database takes place in the head end", Keller explains. Every station carries out its own query concerning the parameters. The Ultimate Version of the Connector with 50 connections is being employed. But even this is not enough for this application, which needs about 200 links. "This is why we have programmed a shared point, which checks the availability of the links", Keller explains. This, in turn, increases the flexibility even more: The stations don't have to share fixed connections anymore. "Only thanks to the SQL4automation Connector we are now able to establish such flexible production systems", he emphasises.
Lots of potential for the fourth industrial revolution
Production at Huba is characterised by complete vertical and horizontal integration. "There is no alternative for the database connection via the SQL4automation Connector", the automation expert stresses. The company INSYS has been using the technology for three years. "The one at Huba is our key system", Keller underlines. "We have collected substantial experience." INSYS carries out up to 25 projects like this every year.
"The database solution with the SQL4automation Connector has enormous potential, which is still not being used enough in automation technology and which is perfectly suited for the fourth industrial revolution", Keller concludes. He is convinced that an intelligent database needs to be at the heart of the fourth industrial revolution.