Digital Schematic Display System
Digital display and control system replacing paper-based production schematics with real-time visualization and direct integration into machine control systems.
- PLC Integration
- Software Development
- HMI Visualization
- System Integration
- Realtime Data
- Custom Hardware
- Germany
- USA
- France
Project Description
For a paper-based manufacturing process, a digital display system was developed that visualizes winding schematics in real time and connects directly to the machine control. The aim was to eliminate manual work steps, reduce errors and significantly increase flexibility in the production process.
The Initial Situation
Winding schematics were created via a dot-matrix printer, manually prepared and aligned on work tables.
Changes required reprinting and replacement of the templates, leading to high effort, susceptibility to errors and limited flexibility.
The Challenge
- High manual effort for preparing and switching schematics
- No guarantee of up-to-date schematics and no version control
- Mechanical constraints due to paper-based processes
- Low flexibility for changes in the production workflow
The Solution
Intelligent display system with integrated production tables
- True-to-scale display of schematics on large-format displays
- Automatic display based on PLC data and recipes
- Real-time visualization of production and status data
- Context-dependent hints to support the operator
Result
The dot-matrix printer and the paper schematics are gone. The right schematic appears to scale on the table as soon as the controller starts the order. Changes to a schematic are maintained centrally and are immediately up to date on all tables. The system is now in use at several sites in Germany, France and the USA.
System design and key capabilities
Benefits for the operator
- No more searching or aligning paper schematics
- Automatic display of the correct schematic at the right moment
- Permanent availability of the latest version
In addition, context-dependent hints and status information are displayed during the ongoing process, helping to prevent errors early and increase process safety.
System architecture & technology
The entire solution is based on a modern, scalable system architecture:
- Central control via a controller PC
- Web-based user interface (HMI)
- Direct connection to the machine control (PLC)
- Distributed display control via dedicated units
- Real-time data provisioning via network protocols
Innovative mechanics: scalable and efficient
A central element of the solution are the newly developed production tables with integrated displays.
- Modular design, individually adapted to the machines
- Folding mechanism for maximum flexibility in the work area
- Installations with up to 14 meters of display length, depicting the schematic fully to scale
- Automatic shutdown of unused displays for energy savings and extended lifetime
Value for the customer
The introduction of the digital display system delivers clear benefits:
- Significantly reduced error rate through guided processes
- Increased efficiency through elimination of manual work steps
- Fast adaptability for changes without reprinting
- Central data management and easy scaling
- Future-proof, digital solution for additional plants and applications
With the new display system, a fully analog, paper-based process has been successfully transformed into a digital, automated and scalable solution.
The result is not only a noticeable boost in efficiency, but also an important step toward more sustainable and future-ready production.
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Electrical engineering and software for industry and production. From Cologne.