Top 5 interface integration use cases in modern production

The integration of interfaces in modern production has developed significantly as a result of digitalization and the increased use of software solutions and IoT devices. While in the past interface integration focused primarily on connecting machine PLCs to the Manufacturing Execution System (MES), today all systems and solutions in the company must be seamlessly connected to each other to ensure efficient and effective production and administration.

In this article, we would like to present the top 5 interface integration use cases in the smart factory. The focus is on practical examples that help engineers and IT technicians in implementing connectivity in production. Dive into the connected world of interface integration with us and find out which areas of responsibility deserve special attention.

2. Machine integration

The oldest discipline of interface integration is the connection of machines and devices to collect signals and data. There are as many interface standards in a production environment as there are different machines. Today, machines and measuring devices deliver high-resolution data at high cycle rates, which need to be processed by production control and management systems, such as MES, ERP and SCADA. Even though OPC UA shows a certain standardization of the interface landscape, traditional manufacturing environments usually consist of many existing machines from different generations and manufacturers and therefore also require different interface standards.

Machine integration can be divided into horizontal and vertical integration. Horizontal integration connects machines and devices in a production line. The focus is on automation, i.e. the transmission of signals that have a direct influence on the processes performed by each machine. Horizontal communication must be particularly efficient (real-time capable) and without delay, which is why standards such as Profibus, Profinet and Modbus are used.

Vertical integration connects machines and devices with software solutions for equipment control and management. These include MES, ERP, SCADA, as well as cloud-based solutions. Most interfaces in this category are based on the TCP/IP network protocol, e.g. OPC UA, REST, ActiveMQ and industry-specific interfaces such as SECS/GEM and EuroMap 77.

2. Application integration

Classic application integration involves software solutions for administration, planning and documentation and is defined by the interfaces of each software solution. Depending on the application, these solutions offer a limited range of interfaces for vertical machine integration. Challenges include a lack of interface standards and the parallel operation of solutions that work with the same data or process flows that need to be connected across departments. For example, product data collected by the MES also needs to be made available to quality management software or summarized as a batch report in the supplier portal. That is the point at which connectivity becomes very difficult without a dedicated software solution for interface integration and data handling, such as FabEagle®Connect.

3. Cloud integration

Regardless of their use case, cloud solutions are characterized by a high level of flexibility. They allow companies to roll out large applications such as ERP, monitoring and equipment management within a few days, as long as the interfaces are available to connect to the cloud. Regardless of whether you are currently using cloud solutions, state-of-the-art scenarios include a cloud-ready approach to digitalization in production. The most commonly used interface for cloud integration is REST API. The REST protocol is based on TCP/IP and provides OAuth 2.0 encryption (authorization framework) to establish a secure connection to the cloud server. Alternatively, systems with unstable networks can also use the MQTT interface, as this can easily buffer data in what is known as a “broker” (MQTT server).

Cloud integration also often involves edge devices or gateways, i.e. devices for connecting the machine PLC and the cloud. The tasks of these devices include data acquisition via the machine interface, buffering data, as well as data processing and formatting, protection through firewall/security and connecting the respective cloud interface. For easy selection of suitable hardware, Kontron susietec® offers prepared IoT bundles consisting of box PCs such as the KBox A-250 and the FabEagle®Connect interface integration solution.

4. Databases and Big Data integration

If an application does not do data processing and data storage, the integration solution may also have to be able to write data sets to databases itself. Relational databases such as SQL DB are most commonly used to record data sets and store complex relations in a straightforward way. Big Data, on the other hand, specializes in different database architectures, all with a focus on storing and processing mass data. To cover the entire application scenario, an architecture needs to be developed specifically and in line with production and the goals set, taking into account data acquisition, storage and evaluation. Factors such as ACID properties (atomicity, consistency, isolation and durability) play an important role here. These properties are intended to avoid errors in data sets or during transactions. However, it should always be possible to write temporary data from a specific machine to a database so that experiments and tests can be carried out easily.

5. IoT integration

New generations of IoT devices and gateways make even more data available using even more complex interfaces. In addition, they break through the traditional structures of horizontal and vertical networking, so that devices on the shop floor are already able to transfer data to cloud applications. This flexibility creates new opportunities, but also new risks when setting up and maintaining a complex IT network. To accomplish this task and make it secure, connectivity, updatability, and security must all be considered. A remedy is provided by end-to-end fleet management solutions for edge devices such as KontronGrid in combination with interface integration solutions such as FabEagle®Connect and secure operating systems such as KontronOS. Ideally, these solutions interlock and form a stable “backbone” in the IoT landscape. The susietec® toolset combines these points with expertise. The solution allows you to monitor the status of all IoT devices via KontronGrid and to automatically and securely update the software used, such as FabEagle®Connect and the Linux® based operating system KontronOS.

6. Integration in a nutshell

In today's smart factory, the requirements for seamless integration of hardware and software are diverse and challenging. From connecting machines and devices to integrating cloud solutions and Big Data, a versatile integration solution for interfaces such as FabEagle®Connect is very helpful. Connectivity is becoming of central importance, particularly in the context of the Internet of Things (IoT). The traditional approach of horizontal and vertical connectivity has evolved to the extent that devices on the shop floor are already able to transfer data directly to cloud applications. A professional strategy that takes security, reliability and adaptability into account is therefore all the more important today. With many years of expertise and the susietec®® toolset, we are able to develop tailor-made solutions that meet the specific requirements of the smart factory.

By using FabEagle®Connect, companies can ensure seamless communication between various IoT devices and other systems while building a robust IT infrastructure to minimize potential risks. In addition, data can be efficiently collected, formatted and distributed as required. The products in the susietec®® toolset therefore make a significant contribution to exploiting the benefits of IoT in manufacturing and increasing efficiency and productivity.

Implementing and utilizing the susietec® toolset products makes a decisive contribution to fully unlock the potential of the Internet of Things (IoT) in the manufacturing industry. This results in companies being able to increase efficiency, maximize productivity, and become more competitive overall.