WERMA MDC systems

Retrofit solutions for transparency in

production processes
Armin Vogelsang
Head of Product Management
Online Webinar
1st August 2016

1.
2.
3.

Presentation with technical

background
Presentation of WIN Software
Open mic for more questions

Why use the WERMA *MDC system?

Obtain greater transparency in your production facility
Monitor the status of all machines, equipment or manual
workstations in a single control station view.
Low cost and easy to install.
Easy to run no programming knowledge required.

* MDC machine data collection system

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Why use the WERMA *MDC system?

Because it is easy to install or retrofit:
Wireless minimal cabling required
No complex changes to existing IT infrastructure
Independent of ERP system or similar
Exisiting signal tower serves as the common interface
Modular design, easy to add further components

Central Control
Station
* MDC machine data collection system
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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Central Control Station offers:

Greater Flexibility

A better overview of

Changes in production quantities are

easier to identify and manage
React more effectively to
product/volume variations

All machines/equipment irrespective of

type
Manual workstations

Comprehensive data analysis

A quicker response
Recognise production issues sooner
Reduce reaction times and downtime
Get help and/or material line side

To identify weak spots and implement

improvements
Makes optimisation transparent

quicker

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

System components
Receiver

Transmitter

Receives all the data sent by

Monitors the status and output of

transmitters in the network

Transfers and saves the data to a
Microsoft SQL database

up to 50 machines or workstations
Transmits data to the Receiver

Software
Control station view of status of

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all machines and workstations

Retrospective analysis of data
Process optimisation
React quickly to production
disruptions
Produce reports

MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Technical background information

WIN network

Frequency band 868 MHz is used (EU) or 915 MHz is used (US).

Transmission range is up to 300 m in the unobstructed line of sight.

Repeater function expands the range to a maximum of 900 m.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Technical background information

Frequency

We use for EU-Version:

US-Version:

Channel 1: 868.15 MHz

Channel 1: 912.997284 MHz

Channel 2: 868.25 MHz

Channel 2: 913.997040 MHz

Channel 3: 868.35 MHz

Channel 3: 915.996552 MHz

Channel 4: 868.45 MHz

Channel 4: 916.996307 MHz

We dont use the complete bandwidth between channel 1 and channel 4

We use a bandwidth of 100 kHz per channel

If you use more than one receiver on one channel, this may cause radio
transmission problems between the systems.

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We recommend to use one receiver per channel.

MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Technical background information

Transmission

Simultaneous sending:

Before sending the system checks by Listen Before Talk algorithm whether
the channel is occupied. If the channel is free, the current status is sent
immediately. If the channel is occupied, the current status will be sent as
soon as the channel is free.

Transmission time:

Sending
immediately

Sending
status

If the status does not change, this is transmitted

Status 1

every 15 seconds.

>3s

If the last transmission is longer than 3

seconds ago, the message is sent immediately.

If the last transmission is less 3

seconds ago, it will be sent after 3 seconds.

No real time system!

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Status 2

seconds

Sending
status

Sending
after 3 s

3s
Status
1

Status 2

<3s
seconds
3

MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Technical background information

WIN network
Benefits

No additional wiring, because of signal transmission wirelessly.

No licence costs, Software can be used on any number of PCs.

Trouble-free operation in addition to WLAN and Bluetooth.

Benefits versus WLAN and Bluetooth

Larger frequency range (300 m) than WLAN and Bluetooth.

WIN penetrates walls and objects significantly better.

Less exposure to radio waves due to lower transmission power.

WIN transmits at 10 mW compared with 2000 mW from a
mobile phone.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Technical background information

Transmitter power

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10dBm (50 Ohm) or 10mW

MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Technical background information

WIN network
Limits

Maximum of 50 machines

Typical wireless restrictions to cable: Can not send over any distance.

Transmission range may be lower on the building quality.

WIN conforms to the EUs EN 300220 harmonised standard and can

thus be used in all EU member countries.
(Further countries upon request.)

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Security

Wireless Security:

WIN is equipped with several protection mechanisms, which prevent the

transmissions being intercepted. In addition, confidential data from the WIN
system will not transmitted wirelessly.

The communication protocol is open, but:

We use a special preamble, only packets with the correct 6-byte sequence are
processed to the WIN System.

Furthermore, a CRC code is calculated and checked for each message. The code is
only known by WERMA.

This means if the CRC code is not correct it will not be transmitted.

Another point is, that the HF protocol of the messages is not known by anybody else

The HF protocol contains the MAC addresses of the WIN devices, the status
information, quantities and a RSSI value with the connection quality information.

The protocols are our basic technology.

We do not provide any kind of protocol to customers.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN slave

Will be integrated into a existing WERMA

signal tower as lowest element.

Transmit up to eight different machines

status warnings wirelessly to the WIN
master.

Every slave simultaneously functions as a

repeater and transmits the signals of
other slaves to the master.
Thus the range to a maximum
of 900 m is expanded.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN slave

Note: The WIN slave uses the electrical connections of the signal
tower.

There are 2 options:

Passive power supply:

If at least one element of the signal tower is always active, the
WIN slave does not need an additional power supply.

Active power supply (recommended):

If there is no passive power supply, the WIN slave needs a
permanent operating voltage, which should be connected to
pin 5, as shown in the diagram below (24V AC/DC).

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN slave performance

Will be integrated into a existing WERMA

1 Counter

signal tower.

Transmits up to six different machines status

warnings and one quantity impulse
wirelessly to the WIN master

Repeater function maximum of 900 m

Counter Input

2 Status
2 Status
2 Status

max. 10Hz
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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN slave performance

Note: The WIN slave uses the electrical connections of the signal
tower.

The WIN slave performance needs a permanent operating

voltage, which should be connected to pin 5, as shown in the
diagram below (24V AC/DC).

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN slave control

The WIN slave control needs a permanent operating

voltage, which should be connected to Pin 1, as shown
in the diagram below (24 V AC/DC).

Pin 1 can be switched through to the terminals 2, 3, 4

and 5. Depending on the pin assignment of terminals 0
and 1 it is possible to switch to 24V or 0V (see drawing).

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN slave control

Every slave simultaneously functions as a repeater

and transmits the signals of other slaves to the master.
Thus the range to a maximum of 900 m is
expanded.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

Troubleshooting
Meaning

LED red

No connection with WIN master

LED green

Connection with WIN master

The blue status LEDs represent the current state

of the individual output. These are only active
if the external switch is activated.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN master

Receives the status and the quantity

of the machines and stores them in
a database.

The WIN master is powered through

the USB port (5V DC) of your PC.

The maximum length of the USB

cable used with the master is 3 m.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN ethernet master

Receives the status and the quantity of the machines and stores
them in a database.

The swap function enables you to integrate the WIN ethernet

master into an existing installation without having to reconfigure the
WIN slaves. The wireless parameters of both devices will be
swapped.

The WIN ethernet master obtains its power through the power supply
supplied.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

Troubleshooting
Meaning

LED red

No connection with WIN slave

LED green

Connection with WIN slave

X
Green LED Ethernet Port

Meaning
No connection to the network

OFF

On

Blinking

Connection to the network

Network activity

X
Yellow LED Ethernet Port

Meaning
No connection to WERMA WIN

OFF
X

Connection to WERMA WIN

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On

X
MDC Systems

WERMA Signaltechnik GmbH + Co. KG

Hardware

WIN ethernet master

The maximum length of the USB cable used with the master is 3 m

and the Ethernet cable shall not be longer than 100m.

General WIN ethernet master information/requirements:

We do not use PoE (Power over Ethernet), therefore we provide a

power supply in the delivery package.

Please be aware that it is not possible to use the WIN ethernet

master as a USB master. Only the configuration is over USB. The data
transmission to the database is over ethernet.

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MDC Systems

WERMA Signaltechnik GmbH + Co. KG

System architecture
MS SQL
Database

WERMA WIN
Mail Service

SMTP

SMTP

Server PC

SQL

Server
Service
24/7

LAN

Connector
Service

USB

TCP/IP

LAN
TCP/IP

TCP/IP

TCP/IP

Connector
Service

24/7

Client PC
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Client PC

USB

Client PC
WIN Training

SP/QM139-03

What is needed to install the sysytem?

Technical requirements
On the machine or
workstation

Within IT structure

Environment

24V permanent supply

Individual client possible

Windows operating

Transmits on 868 MHz

Transmission range up to

to the transmitter on the

signal tower
Receiver connected to
a PC or network
Receiver is powered by
the PC (USB)
PC must be on, with the
software running 24/7 in
order to collect data

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system min Windows XP

Administration rights
required for installation
Always consult IT
department especially
for SQL database and
setting up Email
forwarding function

MDC Systems

300m clear line of sight

Each transmitter will
operate as a repeater
extending range to
900m
For best results Receiver
should be located within
view of Transmitter

WERMA Signaltechnik GmbH + Co. KG

Where can you use the system?

Material Flow

Status Indication and

Call for action
system (Andon)

Production
Monitoring

Visualisation of material

Operator indicates

Automotive supplier with

Overview of complete
operation
Continuous
improvement

Transparency of the
complete production
facility, even if spread
over several buildings
Identify free capacity
Reduce downtime

flow for subsequent

production steps

Optimise material flow

process
Reduce flow time
Make material flow
more lean
Eliminate wastage

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workstation status with

andon light switch set
Machine automatically
indicates status through
signal lights

MDC Systems

120 stations in use

Identify downtime on
machines and
equipment

WERMA Signaltechnik GmbH + Co. KG

Where can you use the system?

Visualisation / call
for action screen

Machine monitoring

Material ready for

collection lineside

Status transmission

Automotive supplier with

Staff activate signal

workstation operational
or out of service
Supervisor support in
event of process
disruption
Reduction in reaction
and downtimes
Increase productivity

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200 machines fitted with

machine data collection
equipment
Analyse productivity
15% increase in
productivity following
introduction of the
system

MDC Systems

when product or
component is ready for
collection
Internal logistics receives
an Email that material is
ready for collection
Reduction in process
time
Optimise workflow
Eliminate waiting time

WERMA Signaltechnik GmbH + Co. KG

You want to try for yourself how it works?

Order one of our sample cases for your trial

Contact

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Manuel Schutzbach
Key Account Manager
Tel. +49 (0) 7424 / 9557 - 153
Fax +49 (0) 7424 / 9557 - 44
manuel.schutzbach@werma.com
MDC Systems

WERMA Signaltechnik GmbH + Co. KG