Automation
Robot control, process orchestration, recipe management and more
Recipe Management
Production orders can be automated using a list of operations that are modeled in a workflow design, allowing (semi-)automated execution on the shop floor.
E.g.: mixing food or chemicals requires accurate execution of recipes that are specific for each product, involving eg dosing ingredients, temperature control, quality checks, stirring and scraping, etc.
While each of these steps can be controlled by an operator via the machine HMI, it is common practice to automate the process in the PLC of the line.
With PearlChain automation it is possible to manage the recipe, by process engineers who don't need to learn PLC programming.
Even better, the process can be graphically designed using a workflow editor (see below), for easy maintenance and version control.
Additionally, recipe templates can be set up, for standardized processes that are maintained once and applied to a variety of products/BOMs. In this case, only the distribution of ingredients across the different process steps needs to be defined for each individual SKU.
The recipe can contain automated steps (via PLC integration/ALC), or manual activities by the operator. This hybrid solution makes sure the system can be used on state-of-the-art, but also slightly less automated installations.
Workflows
Process control across production and logistical activities can be set up by designing workflows that orchestrate activities on the production flow.
Typically the workflows are triggered by an event and will steer automated action by a robot/machine, but it's also possible to include human activities (QA checks, approvals, etc.).
A complete production hall can be steered by the system, acting as a digital supervisor and drastically reducing the required workforce while increasing quality/efficiency.
The complete flow from inbound supply, moving with AGV/AMRs, conveyors or other transport systems, packing/unpacking, wrapping, etc, can be orchestrated by process engineers and without custom development! This means that the process experts can design and implement the automation without the need for a multi-skilled team.
Advanced Line Control (ALC)
The ALC module handles integration with machines and robots with a PLC, by
Instructing the robot/machine which orders to produce, including the machine-level instructions on how to execute the order (parameters)
Capturing what’s going on during the execution
Progress monitoring
Alerts notifications
Registration of production and execution values
The technical architecture allows integration of the other PearlChain modules with the PLCs without the need for 3rd party software, reducing investment costs and overall TCO.
The ALC architecture allows integration with various PLC architectures (Siemens, BeckHoff, Rockwell, etc.), using a queue-based integration pattern.
Where possible, we will propose to use our standard OPC UA connectors as the OPC UA standard provides a secure, open and future-proof set of specifications to integrate the IT and OT world.
AGV/AMR Control
AVG/AMR orders are created and traced by the PearlChain AGV/AMR submodule, which can be integrated with any supplier/brand.
The orders are created from workflows (conditionally, based on events), where the route is calculated and sent to the traffic control system.
Routes be dynamically changed, even when already in execution, in case the route depends on activities that are happening along the way.
Integration with conveyors and automated storage systems can be combined with the transport routes, seamlessly integrating the logistic flows on different installations.
Printers
Printing and applying of labels, pallet sheets, or even directly on boxes, products can be done inline during production, or as part of the logistic process.
PearlChain helps automate these printing processes by sending the correct instructions to the printers, at the appropriate time.
Operators can focus on other activities, while data entry errors are avoided.
Even printing of digital artwork on the final product can be supported.
Conveyors
Conveyors can be automated to move pallets and materials in vessels, ... within the warehouse and the factory.
Using events that are triggered by sensors on the lines, a workflow will steer the behavior of the line, often synchronized with other robots such as AGV/AMRs that transport the material on/away from the conveyor.
The PearlChain system maintains the location of goods in the various sections of the plant and can automatically route materials with steering logic that is set up in dynamic workflows.
Those workflows have at any moment access to the planning of deliveries, production; and receipts, to enable smarter decision-making by the automated flows.
ASRS
Automated storage and retrieval systems can drastically reduce costs and improve efficiency/space consumption and safety.
Using dedicated workflow components for storing/retrieving goods in/out of the ASRS, it is possible to integrate the storage activities into the bigger picture of the entire operation.
The ASRS can act as a black box or can be monitored in detail by PearlChain (including lot/location management)
Packaging Lines
Packaging activities can be highly automated using wrapper robots, pallet staplers, automatic label applicators, material sequencers, etc.
If you want to integrate such a packaging installation, then our ALC integration and process orchestration can be used to create a seamless flow between the packaging process and the previous/next steps in the logistics flow.
The actions can also include additional QA checks and manual activities, ... resulting in a solution that optimizes your process.
