How KnoDTec Enhanced Efficiency and Quality for a Leading German Manufacturer

In today's fast-paced industrial environment, efficiency, productivity, and quality are most important. For companies operating in sectors such as automotive, aerospace, data/telecom, and industrial markets, staying ahead of the curve often requires innovative technical solutions. This case study highlights how a German-based company, partnered with KnoDTec to revolutionize its wire processing operations.

About the Customer:

A leader in providing cutting-edge technical solutions for automated wire processing caters to four major market segments:

• Automotive
• Aerospace
• Data/Telecom
• Industrial

Business Challenges:

They faced several key challenges that necessitated a comprehensive solution:

• Efficiency and Productivity: Streamlining the wire harnessing process to reduce assembly time and automate tasks.
• Cost Reduction: Minimizing material waste, lowering labor costs, and reducing the need for rework.
• Quality Improvement: Enhancing precision and consistency in the assembly process.
• Time-to-Market Acceleration: Speeding up the production cycle to reduce time-to-market for products.
• Standardization and Compliance: Ensuring adherence to industry standards and compliance requirements.

KnoDTec's Solution:

To address these challenges, KnoDTec developed a sophisticated software solution and rebuilt the product with a user-friendly Human-Machine Interface (HMI) web server for easy access and configuration within a LAN network. The solution focused on improving data acquisition presentation speed and performance. Here are the key components developed and integrated by KnoDTec:

• Firmware Development for Main Controller Unit (MCU)
• Serial Communication Module – RS485
• Communication Protocol Module
• Diagnostic Information Handling and Hardware Diagnostics
• Backend Scripts
• UI/UX Design
• Software Development – Web and API
• Database – SQLite
• HMI for Touch Screen Display
• Google Blockly Integration

KnoDTec's team was involved in the firmware development, HMI development, web application development, verification, and validation processes.

Result:

The project was completed, yielding significant benefits.

• Automation of Wire Harnessing: The process was streamlined and automated, drastically improving efficiency.
• Enhanced Control: The user interface of the HMI screen provided complete control over the device.
• Web Application Configuration: All wire details and settings can be configured through a web application.
• Seamless Data Retrieval: Configured data could be retrieved from the web to the HMI screen using the API layer.
• Testing Capability: Google Blockly integration allowed for easy and fast test runs.
• Firmware Upgrade via USB: Simplified the process of firmware updates.
• Additional Functionalities: Python scripts enabled printing labels and playing audio.

Tools and Technologies Used:

•  Operating System: Linux
• Firmware Development: C / C++
• Web Development (Web and API Layer): ASP.NET Core
• Protocols: MQTT
• Programming Language: Python
• HMI Development: LVGL
• Testing and Automation: Google Blockly

Through its partnership with KnoDTec, our client was able to significantly enhance its wire processing operations, leading to improved efficiency, reduced costs, and higher product quality. This case study demonstrates the profound impact of integrating advanced software solutions and automation technologies in industrial applications.