What were the challenges to be solved and what specific benefits were achieved?

Today end users demand flexible and cost-efficient production and logistics – even in case of individualized products. The time to launch new (consumer-) products on the market becomes increasingly shorter. For suppliers of machines and systems this results in the requirement to reduce development and commissioning times. At the same time high productivity and flexibility up to batch size 1 have to be provided and reliable machines have to be supplied. This development also concerns Lenze Automation GmbH as a technology supplier for machine and plant construction. Suitable products as well as precise services have to be offered to customers. For this Industrie 4.0 technologies such as the Application Software Toolbox (FAST) are used. The toolbox consists of technology modules (TM) for functional mapping of mechatronic units of a machine or plant. By this motion functions of a machine with its machine modules can be realized by standardized application software modules, which can even be reused. The technology modules cover all motion profiles: Single-axis, such as positioning, two-axle, such as cams and multi-axle robot applications, such as palletizing. The work of the software is based on pre-fabricated, tested, documented and version-controlled technology modules. According to the principle “buy what you need” customers only buy those TM, which are required. Further TM can be loaded via Internet – also in later operation.

How can the Industrie 4.0 approach be described?

The technology modules had been created in a standardized programming language and are treated as a product by Lenze. Generally all TM are included in the control. The required parts are activated by a license model. The know-how of the user can be added by own software. In order to support the modularity, Lenze uses object-oriented techniques for Industrie 4.0 applications. As needed further TM can be loaded and activated by the user via Internet.

What could be achieved?

The software toolbox developed by Lenze offers several advantages for users:
It reduces development times by pre-fabricated functions, decreases test expenditure by pre-tested functions and interfaces and guarantees easy use (“parameter setting instead of programming”) as well as scalability.
In addition to this the software quality is improved by open standards, a predetermined program structure and version-controlled, pre-tested TM. Moreover the TM already cover all standard motion functions of a machine, special user know-how can be implemented by own (capsulated) TM. The TM do not only provide the function itself, they also enable data generation and data exchange, for example of diagnostics data.

In general machine software becomes scalable, modular and reusable by using Industrie 4.0 technologies. The standardized structure enables transparency, which also simplifies the analysis in case of maintenance or failure.

What measures have been taken to achieve the solution?

Lenze used available programming standards such as IEC 11631 and PLCopen. At the same time, Lenze used object-oriented techniques, which support the modularity of the machine. The TM are treated as a product (tests, releases, version-control, documentation).

When delivered the machine control only contains the required operating software, all needless software elements had been removed. All TM are available for the machine control. By means of a license model only those are activated, which are required for this application. As needed, further TM can be loaded via Internet in later operation.

The structure of the machine control enables data exchange with superimposed systems, assistance systems, etc. – also in this case via standard mechanism.

What can others learn from it?

When developing the toolbox Lenze considered the requirements of the users: Simplicity in the application, reduction of complexity and increase of flexibility. Easy generation of versions and reuse of created software had been focused. Furthermore Lenze respected, that the requirements of all phases of the machine cycle (conception, realization and operation) are covered.

The general challenge is to keep or even increase the simplicity of the application in spite of increased requirements toward machines – especially in view to functionality and flexibility.