case study
11.06.2024
the HEKUMA Automation Designer
The development of automation software in special machine construction is associated with high costs due to the complex requirements for machines and processes. Industry-standard solutions, such as the use of software project templates, are time-consuming and do not create perfect standardisation. HEKUMA is one of the leading technology companies in Germany in the field of high-performance automation for the plastics industry. The company has recognised the weaknesses of standard industry solutions and, together with typedigital, has developed an application that considerably simplifies the development of software projects for special machines by generating executable control software from simple machine configurations. This means that the initial automation software, which is already customised to the machine and the production process, can be created with a cost saving of up to 20%.
backend
<h2>Motivation</h2>
<p>HEKUMA is a special machine manufacturer for automation in the plastics industry. The company from Hallbergmoos, near Munich, specialises in the high-speed removal of plastic injection moulded parts and their further processing. Each machine manufactured by HEKUMA is developed for the individual manufacturing process of the parts to be produced.</p>
<p><img src="https://typedig.uber.space/assets/bf69f8ce-0f68-489a-b110-5f5063d28928?width=4724&height=2108" alt="M K4 2627 (2)"></p>
<p><em>This special machine is from the medical technology sector and produces a type of sheath for surgical sutures</em></p>
<p> </p>
<p>Due to the immense variety of manufacturing processes and applications for customised machines, a great deal of effort was required to develop the system software.</p>
<p>As a result, the further processing of the plastic injection moulded parts is highly adapted to the product to be manufactured. Neither the type and quantity of components used nor their sequence in the machine can be easily standardised. As a result, almost every customised machine is unique. This contrasts with series machine construction, which is characterised by a high degree of modularity and standardisation. Compared to series machine construction, special machine construction is characterised by the fact that individual development is indispensable in all production phases - and therefore also in software preparation and commissioning.</p>
<h2>Problem definition</h2>
<p>As the machines differ greatly in terms of their design and the components used, a great deal of work is involved in preparing the software and commissioning the machines.</p>
<p><img src="https://typedig.uber.space/assets/3b0d8735-9b96-4102-92e7-80c7a14b47eb?width=886&height=590" alt="193568 Greifer 1 Low (2)"></p>
<p><em>This special machine uses a special gripper that removes parts for further processing</em></p>
<p> </p>
<p>Best practice in the industry to date has been based on template projects in order to obtain a usable shell of a software project for the system with as little effort as possible, which is then specifically adapted and expanded.</p>
<h2>Procedure</h2>
<h3>Project setup</h3>
<p>The typedigital team was integrated into the HEKUMA project team from the outset in order to facilitate an intensive exchange of knowledge and create a cross-team perspective on system development problems. Joint engineering was one of the most important key aspects for the success of the project.</p>
<p>This enabled the individual project phases, in particular the optimisation potential of software preparation and commissioning through standardisation, to be analysed together and initial solution approaches to be outlined.</p>
<h3>Course of the project</h3>
<p>The first task consisted of designing the Automation Designer, a desktop application for modelling the system and its assemblies. It was important to ensure that entire assemblies, alarms and safety systems as well as atomic components and their parameterisation could be modelled in advance using this application.</p>
<p><img src="https://typedig.uber.space/assets/65935c79-4445-410f-ae14-12232d89f3fd?width=1920&height=1280" alt="Typedigital Zunder Foto 20230628 109"></p>
<p><em>The project required intensive collaboration between typedigital and HEKUMA</em></p>
<p>Together with the PLC modules developed by HEKUMA, an executable control code could be developed for each individual component.</p>
<p>Furthermore, a customised file format was developed to persist all the data of a system and distribute it to the members of the team. </p>
<p>An automated release and update mechanism was also implemented, which can be used to roll out new features to users, for example.</p>
<h3>Solution & outlook Technology highlights<br>Electron</h3>
<ul>
<li>JavaScript/Typescript</li>
<li>React</li>
<li>Node.js</li>
<li>TIA Openness</li>
</ul>
<h3>The Automation Designer</h3>
<p>Since its release, the Automation Designer has established itself in the company's software department. By the time this success story was written, six machines had already been realised with it. During the pilot phase, it became clear early on that the use of Automation Designer could save around 20% of working time compared to the old process.</p>
<h3>What's next?</h3>
<p>The plan for the near future is that Automation Designer will be able to support further TIA versions. It will also be constantly expanded to include further modules in order to be able to offer even more components.</p>
References
what hekuma says about us
<p>"As an industrial company that produces special machines, we need a strong partner who can quickly familiarise themselves with industry specifics. The typedigital team fulfilled our high expectations in an outstanding way, because the joint development of a software generator for special machine construction - a complex task - was mastered with flying colours. We can therefore warmly recommend typedigital to any company, as the collaboration is extremely enriching both professionally and personally."</p>
Product Owner "Automation Designer"
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