Cooperation in Industrial Automation with Siemens

The demands of the industry are high: Our customers handle products that they cannot describe exactly in advance. Therefore each fish is measured individually and this data is used to calculate the best parameters for processing.

During development, we create a digital twin that supports us, with all its advantages, throughout the entire product development process and its lifecycle. It allows to test functions and verify ideas right at the start of every concept phase. We standardized our programming and software architecture in collaboration with Siemens, e.g. we implemented PackML as the standard for machine sequence behavior and communication with line controllers. As a result, implementing functions has become significantly more structured, ensuring faster deployment and enhanced flexibility. Our faster development cycles and more efficient processes ensure that the best possible new machines are ready for the market more quickly. ‘With this future-proof approach we can focus on what matters most — developing better solutions for our customers, including the best service and efficient project implementation.’ says Nils Kuehnel, CTO & Managing Director Fish.

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Standardization in Industrial Automation

In general, standardization is the key to efficient processes. At machine level, standardization enables the optimization of processes. At line and system level, it facilitates line integration and modification through a common architecture and open interfaces. And at company level, standardization helps to monitor and compare performance and leads to more efficient and sustainable production.

At BAADER, the standardization of the machine program for the fish machines includes the structuring of the program code. The machine programme is structured in accordance with the ISA88 automation standard, which allows a modular programme structure. The implementation of the OMAC PackML state machine requires operation mode-dependent programming in order to promote the clarity of the programme structure. This structure provides all programmers and after-sales service experts with a standardized ‘look and feel’. Furthermore, the structure is predefined and the actual functions that map the process only have to be developed.

‘The standardized programme structure also supports collaboration’, says Thomas Raths, Head of Automation and continues ‘The developers can now quickly find their way around a project and thus provide more efficient support in the event of a customer enquiry. Of course we also benefit from the fact that we always talk about standardized functions when coordinating with other areas such as mechanical design. Everyone knows immediately what it's all about.’

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Digital Twins at BAADER

At BAADER we see the digital twin as a digital representation of one machine or processing line in shape, function and physic behaviour model. The digital twin supports us throughout the entire product development process, even from concept phase to field support.

‘The digital twin helps with development. For many development steps, we do not always require a physical machine, even we can find and fix bugs more quickly.’ explains Thomas Raths, Head of Automation.

BAADER uses the NX Mechatronics Concept Designer and SIMIT tools from Siemens to kinematize the models and simulate the machine behaviour. The standardization of machine projects is an important building block for digitalization - as is a standardized process for the digital twin. ‘For example, we can use the Simulation Model Generator to automatically generate a SIMIT simulation model from information from the TIA Portal project. That already maps a lot,’ confirms Hendrik Hansen, Technical Expert Simulation. However, the digital twin is not only important for development, adds Raths: ‘It also gives us the opportunity to test extensions and updates in in advance without a physical machine before we implemented at customer machine - and that is a huge advantage, because the systems are often located in very remote locations.’

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Machine Language in Industrial Automation

PackML (Packaging Machine Language) is a standardized control and communication model for machines. For machine builders, it simplifies machine integration by providing a common framework for machine states, modes, and data exchange. This reduces complexity, improves compatibility between machines, and speeds up development and troubleshooting across different systems in processing lines. The look and feel of machine operation should be consistent.

BAADER integrated an OMAC PackML manager in the machine software architecture, the machinery programme is executed in accordance with the PackML state machine. ’At first glance it certainly seems more complex’ explains Raths, but the advantages with PackML und ISA88 architecture could be recognized quite early. Further developments and expansions of machine programme could be implemented much easier.