Control systems (INGENIA)

Control systems (INGENIA)

Control systems

Module:

SAP linkage

Reporting

Graphical user interface

Capture & replay

Detailed planning and control

Simulation

Maintenance

Custom modules

 

Technical details:

Full access to production data (BDE)

Improved SAP linkage
Open (licenced) Interfaces, web services

Energy management
Production (load management, energy peaks management, …)

Ingenia control software contains all the functions that are essential to an optimised galvanising process. Via WLAN, a main PLC with central control logic directs the individual transport and travel units in an “automatic” or “semi-automatic” mode. These can also be addressed manually, for example during servicing, using remote radio control.

IMES – the modular extendable software package
The Ingenia Manufacturing Execution System (IMES) represents an intelligent, efficient and individually adjustable link between the company management and production Levels.

Among other features, IMES incorporates resistant data storage. Therefore all relevant data can be called up on an ERP level and be passed on to the company management.

SIMULATION AND VIRTUAL START-UP

This software package, which was specially developed for material flow planning and simulation, tests and optimises control system software, thereby reducing start-up times considerably. 

The package is capable of testing and comparing differing scenarios and layouts in order to detect logistical bottlenecks and potential deadlock situations (plant downtimes). Strategies for efficient Interim buffering and tour planning can thus be developed.

If recipes and production sequences are entered, for example for five weeks of operations, within just a few hours the software delivers a complete simulation. This allows the determination of valuable data regarding subsequent production reality and critical operating situations can be subjected to preventive testing. The industrial PC guides the simulation system with the control software already designed for actual operations.

Visualised simulation of actual plant

Plant layout optimisation

Logistic sequence optimisation

Optimisation of transport unit numbers

Control software development

Control software testing

Linkage of the simulation model with the control system

Identification of logistical bottlenecks

Identification of deadlock situations

Feeding of software into the control hardware

Avoidance of complex programming

Reduction in start-up times using simulation to approx. 2 weeks (instead of 8 to 9 weeks)