Process data visualization is essential in modern production environments. With the IoT platform ALD EXPERT GRID, machine and production data can be monitored, analyzed and optimized in real time.
The challenge: Process monitoring and fault detection in real time
Especially in the aerospace industry, high demands are placed on products, as well as on the systems used there. The special machine manufacturer ALD Vacuum Technologies GmbH develops and designs systems in which components made of a nickel-based alloy (superalloy) are coated with wafer-thin ceramic. The system works with high temperatures and special coating techniques.
ALD’s customers require real-time monitoring of the production process in order to detect errors in the coating process immediately and thus be able to derive recommendations for action while the process is still running. Currently, deviations are detected and smoothed manually by a machine operator, which requires a lot of time and manpower. Although the coating can be removed later, this is very time-consuming and therefore more expensive than the coating itself.
The solution: Real-time visualization and data analysis with ALD EXPERT
With Industrial IoT technologies, this expense can be avoided before it even arises. ALD EXPERT acts as a web-based IoT platform that connects machines and devices in different production environments, collects their data and analyzes it. One of the core functions is the central visualization of process data. Data is usually recorded via the system’s PLC, whereby ALD EXPERT can be used to address almost all controller types of different generations. The data is permanently forwarded to a central host (ALD EXPERT GRID), which in turn sends it to analysis software for processing. The data is usually visualized via dashboards, which present both historical and current data in a user-friendly way and make it available to the user. The comprehensive and clear presentation of the process data enables a quick response to any problems or inefficiencies that arise. By using various sensors, additional machine and process data such as temperature, pressure and gas can also be determined and visualized.
Integration into other machines and applications
By employing an open architecture, both standardized protocols (such as OPC UA) and custom, customer-specific interfaces can be seamlessly integrated. The ALD EXPERT GRID can therefore also be easily integrated into systems from other manufacturers.
A key element of the solution is the ability to seamlessly connect machines from different manufacturers. ALD EXPERT uses an open architecture that enables connection via standardized protocols such as OPC UA as well as specially developed interfaces. This flexibility means that not only ALD’s own machines and systems, but also third-party machines/systems can be integrated into the system.
Another advantage is the integration with existing ERP and MES systems. This allows production data and orders to be exchanged between the various systems in real time, ensuring seamless automation and documentation of the entire production process. The synchronization of production recipes and central data management significantly improve quality assurance.
Data processing in a modular on-premises solution
The platform has a modular structure: Companies only use the functions that they actually need. The modules include “Condition Monitoring”, which enables predictive maintenance of the machines, and the “Advanced Observation System” (AOS), which integrates camera-based process monitoring and automated anomaly detection. These modules can be operated independently of each other and expanded as required, offering the customer maximum flexibility.
Data processing and storage at ALD EXPERT are carried out using an on-premise solution, ensuring that all sensitive production data remains directly on-site with the customer. This is particularly beneficial for companies in highly regulated industries, as it allows them to maintain full control over their data while meeting strict compliance requirements. The data is stored in a central database, from which comprehensive reports can be generated and exported into formats such as PDF as needed.
The result: Improved efficiency and quality assurance
The use of the ALD EXPERT GRID platform leads to significant improvements in the efficiency and quality of production processes. By monitoring machine conditions and production parameters in real time, companies can react more quickly to deviations and minimize downtimes.
Early detection of anomalies and proactive maintenance significantly reduce unplanned downtimes and help to extend the service life of machines and systems. This leads to higher availability of the production systems and a significant reduction in maintenance costs.
In addition, the central management and visualization of process data enables better traceability and traceability of all production steps. This is particularly important in regulated industries, where strict requirements are placed on documentation and quality assurance.
