The biggest challenge of digitizing most plant facilities is the multitude of different systems. Many machines are often several years old and come from various manufacturers. The systems are often not designed to be digitized.

We achieve digitization through our proprietary hardware and software combination. Our SPARK is an edge device that we connect directly to the different systems. With our product, the data from the machines can be collected, recorded, and visualized.

Why plants are so rarely digitized

Many machines could technically be read out, even though the machine manufacturer never intended it. However, many production companies cannot estimate the maintenance effort (and thus the costs) of such a solution.

This leads to the IT departments of these companies often being overwhelmed, and such a project is never even started. Especially in mechanical engineering, no two systems are alike, and custom manufacturing is more the rule than the exception.

Nevertheless, digitization in production today is indispensable – as controlling often requires machine data about, for example, actual material consumption to make correct decisions, and in production, data analysis could often lead to more productive manufacturing than is usually the case.

Comprehensive portfolio of connectors

For this reason, we have developed SPARK and our extensive portfolio of connectors, which is continually expanded. When connecting systems, we take a unique approach, as we connect directly to the controls and automation systems of the machines and decrypt the protocols to make the data available.

This approach also allows us to read out systems that were never originally intended for this. Additionally, our passive connectors enable the reading of process data even in cases where active intervention in the machine communication is not possible or not desired.

Various data sources reconnected

Via the edge device SPARK, all shop floor data sources can be linked and recorded. This includes PLC data, as well as various sensors present in the machines, inline quality and data systems, and file servers. The SPARK connects all systems together and records the data in the cloud.

Machine data in conjunction with BDE and controlling data

Context is King: The machine data read out with SPARK is linked by our software with the accounting data. This makes it clear how a specific product was produced on which day. Moreover, the machine data can also be compared with productions on other days.

This has several advantages:

• Correct and uniform data facilitate material purchasing

• Machine data from individual orders can be compared

• Optimizations can be specifically derived

• Traceability of individual production orders

From hardware to integration - everything from one source

Unlike other providers, we develop all our software ourselves, from data reading to the dashboard. This allows us to offer a unified solution for a machine park with systems from different manufacturers.

Our strength lies particularly in our ability to implement custom solutions. It does not matter whether they are rare or custom-made machines for very specific requirements.

We are not bound by restrictions from the machine manufacturer. The only limit here is the technology itself.

Complete solution instead of modular system

With us, producers do not have to worry about having many different contact persons for the individual components of the digitization solution. We do not offer individual components but a complete solution.

For this reason, with us, there is also only one contact person for the entire system. This not only provides good clarity but also allows for cost planning.

Also hardware solutions for special machines

If our existing product does not lead to the desired goal, a cost-effective hardware solution is often possible to obtain the required data. We also develop hardware solutions for reading specific machines.

Which systems/technologies are supported by SPARK?

Here you will find a brief overview of the systems and technologies currently supported by SPARK. We are constantly expanding this.

• ABB/Gossen-Metrawatt control systems

• Allen-Bradley controllers

• B&R PVI-based Windows systems

• Beckhoff controllers

• Digicolor / Ferlin Gravimix

• EtherNet/IP

• EtherCAT

• Hosokawa Alpine ExVis

• Kdesign VARIOcool

• Keyence Vision image processing systems

• Macchi blown film extrusion lines

• Mitsubishi FX controllers

• Modbus

• Motan dosing, mixing, and feeding systems

• OPC DA / OPC UA

• Plast Control ACS

• Siemens S7-1200/1500 controllers (S7 Plus)

• Siemens S7-200/300/400 controllers (S7 Classic)

• Windows DDE communication

• SBI thickness measuring systems

• Omron controllers

• Weber WPS

If you have other systems, please contact us. We are constantly expanding our capabilities for integrating your infrastructure.

ℹ️ What happens to the read-out data?

Connecting controls and reading data through the protocols is only the first step. Additionally, the correct variables and parameters must be identified, correctly named, and scaled to make usable derivations for production. We have also developed intelligent solutions for this, so that the correct data recording can be done quickly and tailored to the needs of the producer. Any later changes are also easily implementable for us without significant effort.