How open must or should an automation solution be?
- Automation
- Digitalization
- 30.11.2023
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Contents
Every industry has unique requirements when it comes to industrial automation, and the technical complexity is constantly increasing. The trend towards ever smaller order batches, customized products and shorter delivery times present companies with major challenges. Traditional line production is often less productive and requires more control when customer requirements change and need to be responded to quickly. There is an increasing demand for flexible production cells and production processes that enable a wide range of product variants and scalable quantities. These production processes are characterized by a constant increase in the level of automation. On the one hand, the integration of drive, measurement and sensor technology, as well as computing power and the necessary establishment of standardized information and software technology, which is becoming increasingly important.
The software component of an automation system increases significantly, especially when controlling complex production processes. However, this requires a more flexible and open system architecture for the automation solution used so that existing hardware and software components can continue to be used and expanded. Scalable and manufacturer-independent automation solutions are playing an increasingly important role in the overall automation strategy, because in times of vulnerable supply chains and the associated dependencies, many companies are increasingly focussing on a multi-supplier strategy.
Challenges in the selection and integration of hardware and software components for a holistic and scalable automation solution
Numerous challenges arise when integrating all hardware and software components of the production environment into a common system:
- Possibilities for sufficient data collection and data evaluation in order to optimize automation processes
- High demands on the security of IT systems (especially for cloud connections)
- Increasing need for sustainable production and the implementation of directives and regulations (e.g: EU Machinery Regulation, Cyber Resilience Act, EU Green Deal, ESG ratings, ...)
- Increasing the flexibility and quality of the production process in order to remain competitive
- Lack of acceptance among employees for "new" systems
Shortage of skilled labour and less qualified personnel for increasingly complex and flexible production processes
Increasingly "interchangeable" hardware components and thus decreasing differentiation from competitors
What is needed is a common and software-based "ecosystem" that must be flexible, transparent, scalable and, above all, open.
What is necessary for the successful implementation of an automation system?
For the successful implementation of a modern automation system such as Kemro X, the simple integration of hardware into a higher-level system is no longer sufficient. What is needed is a common and software-based "ecosystem" that must be flexible, transparent, scalable and, above all, open. Independent of different manufacturers and suppliers - because this is the only way that all hardware and software components can work together seamlessly to optimize and control an automated production process.
An open ecosystem for modular automation
In an open overall system, hardware and software are combined to form modular overall solutions that can be used to solve individual challenges. At KEBA in the form of a "modular system" that provides the basis for many industry-specific solutions - this probably best describes Kemro X. This automation solution includes applications, software engineering tools and hardware components and, thanks to its flexible system architecture based on a Linux platform, can be supplemented with the core expertise and technologies of third parties. KEBA has decades of in-depth industry expertise and designs specific solutions that can be reused and expanded. As a result, more and more modules are being created on the Kemro X platform, enabling industry-specific packages that are tried and tested, adaptable and quickly ready for use. Cleverly combined, the Kemro X modules can be used to solve a wide range of automation requirements.
The core of Kemro X is the open control software platform based on Linux. Linux is widely used and customized automation solutions based on Kemro X can be implemented very easily even without much knowledge of Linux. Interoperability with KEBA hardware (e.g. controllers, IO modules, drives, servomotors, etc.) works perfectly and, thanks to the Ethercat, Ethernet IP and Profinet standard interfaces and the open system architecture, customers are no longer dependent on just one supplier. Customized software modules and third-party software can therefore be integrated more easily. However, hardware products such as the KEBA KeDrive controllers and KeTop HMI solutions can also be operated with 3rd party controllers (via EtherCAT, Powerlink, Profinet). This makes it even easier to gradually switch to an open automation system.
Who is Kemro X suitable for and what needs to be considered?
For all machine builders who need automation solutions that are future-proof, scalable and compatible with existing software and hardware components. Those who, due to increasingly complex processes, need complete solutions from a single source, but without having to worry about becoming "dependent" on a single overall supplier or manufacturer. Kemro X is particularly characterized by the ability to integrate your own software modules and third-party software at any time. Complex customized solutions are not always necessary - Kemro X contains many tried-and-tested standard modules and applications that can be adapted quickly and easily, thus saving time and money on implementation. In addition, Kemro X is also available as a pure PLC (programmable logic controller). If the customer does not have its own in-house resources available, KEBA is a reliable partner at eye level, providing support from the initial design through to series production. Joint project management, workshops, training, joint source code management and the synchronization of roadmaps and sprint planning have proven to be extremely effective in the collaboration.
Even though integrated automation systems such as Kemro X are constantly being developed further, there are a few things to bear in mind when it comes to the interoperability and integration of 3rd-party hardware and software. Even if a standard protocol such as the DS402 drive profile is supported, it is possible that not every drive behaves in exactly the same way and minimal adjustments may be necessary. The same applies to the integration of PLC source code based on the IEC 61131-3 standard. When adopting 3rd party or open source code, care must be taken to ensure that the real-time capability of the overall system can be guaranteed. KEBA has gained a lot of experience in this area and offers corresponding guidelines. Although the openness of Kemro X means that "older" protocols can usually be adopted, consideration should be given to switching to more modern and future-proof protocols.
