Does your industrial automation system feel rigid and complex, hindering your path to true Industry 4.0 adoption? The traditional methods of programming and interfacing with Programmable Logic Controllers (PLCs) have long presented challenges, often limiting flexibility and user-friendliness. However, a significant shift is underway, as highlighted in the video above, with innovations like Open Core Engineering by Bosch Rexroth.
This groundbreaking approach introduces a new paradigm for flexible automation engineering. It involves directly accessing the control core of PLCs, going far beyond previously available methods and tools. This move is seen as a courageous step, effectively opening up the PLC market for truly PLC-independent programming.
The Dawn of Open Core Engineering
Open Core Engineering facilitates unprecedented access to the very heart of the control system. High-level programming languages can now be utilized to address and influence the PLC’s control core directly. This capability ushers in a new era of complex and flexible automation solutions.
A gateway toward advanced Industry 4.0 applications is thereby opened. With Open Core Engineering, the creation of unique user interfaces, known as apps, becomes feasible. These interfaces diverge significantly from existing industrial manufacturing environments, promising more intuitive and simpler machine operations.
Bridging the IT/OT Gap with High-Level Programming
One of the core advantages of this technology is the direct access it grants to all variables and core functions of the PLC. This expanded accessibility is made possible through the integration of high-level languages. For instance, critical functions such as reading axis parameters and diagnostic information can be performed with greater ease.
Direct Access to the PLC’s Core Functions
Beyond simple data retrieval, direct access to motion components is also provided. This allows for precise control, enabling axes to be moved and managed dynamically. Such comprehensive control capabilities are instrumental for modern, responsive automation systems.
Beyond Traditional PLC Languages
Complex logic can now be efficiently transferred from the PLC environment to high-level programming languages like C++, Python, or Java. This is because certain programming tasks are considerably simpler to achieve in these advanced languages. Traditional methods such as ladder diagrams, order lists, or structured text, while foundational, often present limitations when dealing with intricate algorithms or advanced data processing.
The ability to leverage these languages enhances programming flexibility and accelerates development cycles. It allows for the implementation of sophisticated control strategies that might be overly complex or cumbersome to develop using conventional PLC programming tools. This ultimately leads to more agile and powerful industrial automation systems.
Open Core Engineering as an Industry 4.0 Enabler
The flexibility offered by Open Core Engineering is perfectly aligned with the principles of Industry 4.0. It facilitates a more interconnected and intelligent manufacturing environment where machines can communicate seamlessly. This advanced connectivity supports the collection and analysis of vast amounts of operational data.
Furthermore, the development of custom applications enables adaptive manufacturing processes. Production lines can be quickly reconfigured to meet changing demands, supporting mass customization and improved resource utilization. This paradigm shift helps companies to fully realize the potential of digital transformation within their operational technology (OT) landscape.
Revolutionizing User Interfaces and Machine Operation
A key benefit of Open Core Engineering lies in its capacity to transform human-machine interaction. User interfaces can be designed to be highly intuitive, drastically reducing the learning curve for machine operators. This directly translates into significant savings in training costs.
Intuitive Apps for Industrial Environments
The development of specialized apps ensures that machine operations are not only simpler but also more engaging. Operators are presented with visually appealing and easy-to-understand interfaces, which can significantly boost motivation. This approach moves away from often intimidating industrial HMI (Human-Machine Interface) designs.
The Power of PLC-Independent Programming
Moreover, the design of user interfaces can transcend linguistic barriers. By minimizing or doing without linguistic elements, these interfaces become universally understandable. This aspect is particularly valuable in global manufacturing networks, where diverse workforces operate machinery across different regions and languages.
The independence from specific PLC programming environments means that applications developed can be more portable and adaptable. This streamlines system integration and maintenance across various industrial setups. Such flexibility is crucial for enterprises operating in a globally interconnected market.
Real-World Impact: A Case Study in Action
A compelling example of Open Core Engineering’s practical application is a joint project between Bosch Rexroth and Glaub Solution GmbH. This collaboration resulted in a specialized solution for Maturo, a prominent manufacturer of brake testers and dynamometers. The project illustrates the real-world advantages of this innovative technology.
Bosch Rexroth supplied the essential hardware components and drives for the system. Glaub Solution GmbH then developed a sophisticated user interface based on C++, which accessed the control unit via Open Core Engineering. This integrated approach allowed for a highly customized and efficient solution.
The developed system went beyond a mere user interface; it also provided comprehensive management of test cycles and test processes. Associates at the test bench were thus empowered to configure and manage testing procedures precisely as needed. This level of configurability significantly enhances operational efficiency and data accuracy in critical testing environments.
Future Prospects: Enhancing Production Automation
Significant opportunities are identified within the broader realm of production automation with Open Core Engineering. Machines can be equipped with optically attractive user interfaces that are not only functional but also enjoyable to use. This aspect directly contributes to increased associate motivation, fostering a more positive and productive work environment.
The capacity to create such engaging interfaces can transform repetitive tasks into more satisfying experiences. This leads to higher job satisfaction and potentially reduced errors. Automation systems become tools that empower workers rather than just replacing manual labor.
Furthermore, the inherent flexibility of Open Core Engineering supports rapid prototyping and deployment of new automation solutions. Custom applications can be developed and integrated much faster, allowing manufacturers to respond swiftly to market changes. This agility is a powerful competitive advantage in today’s fast-evolving industrial landscape, driving continuous innovation in flexible automation engineering.
Open Core Interface: Your Flexible Automation Q&A
What is Open Core Engineering?
Open Core Engineering is an innovative approach that allows direct access to the control core of industrial Programmable Logic Controllers (PLCs). It enables programming with high-level languages, making automation more flexible.
Why is Open Core Engineering important for industrial automation?
It helps make industrial automation systems less rigid and more adaptable, moving beyond traditional PLC limitations. This approach supports the creation of advanced solutions and helps in adopting Industry 4.0 principles.
What kind of programming languages can be used with Open Core Engineering?
Open Core Engineering allows developers to use high-level programming languages such as C++, Python, or Java. This is a change from traditional PLC-specific languages, making complex tasks simpler to achieve.
How does Open Core Engineering improve machine operation for users?
It allows for the creation of intuitive and user-friendly interfaces, often called apps, for industrial machines. These interfaces simplify machine operation, reduce training time for workers, and can make tasks more engaging.