Success Stories & Case Studies

Automated Cutting Machine HMI System (CC05 SmartLink) The Challenge: The client required a modern Human-Machine Interface (HMI) to automate the workflow of their CC05 Cutting Machine. The system needed to bridge the gap between operator barcode scanning, centralized production databases, machine PLCs, and label printers in a seamless manner. Key Difficulties: Establishing direct communication with Mitsubishi FX5U PLCs over a TCP/IP LAN without relying on expensive third-party OPC servers. Automating the label printing process by sending raw commands directly to Zebra printers without using standard Windows print drivers, ensuring zero delay. Providing robust offline capabilities for operation history logging and instant label reprinting in case of hardware or network issues. Solution Architecture WP Solution developed CC05 SmartLink, an industrial-grade C# .NET 8 WPF application acting as a comprehensive middleware HMI. The workflow is entirely barcode-driven; operators simply scan a Control Number or Order Number to automatically retrieve production parameters (such as Cut Length, Project No, and Model) from a central SQL Server. Once the machine is commanded to start, the system communicates directly with the PLC, listens for the “Machine Complete” signal, and dynamically generates and prints Zebra ZPL labels. ...

Knuckle Production Data Link System The Challenge: An “Automotive Tier 1 Manufacturer” required an automated digitalization system to record Scan-In/Scan-Out times for Knuckle parts during the CNC process. All data needed to be stored in a central database for full traceability. Key Challenges: Legacy System Integration: The existing production line utilized Mitsubishi Q-Series (Q03/Q06) PLCs, which were difficult and costly to modify. Data Logic: Clearly separating Left-side and Right-side production data, then synchronizing them at the final Visual Inspection stage. Efficiency: Data transmission must be seamless without affecting the machine’s cycle time. Solution Our team implemented a “Direct Integration via SDK” strategy. We developed a custom C# (.NET) Application to communicate directly with three Keyence SR-2000 scanners using Socket (TCP/IP) protocols. This “Non-Invasive” approach allowed us to extract production data without interfering with the client’s original PLC logic. ...

High-Speed OCR & Barcode Verification Problem Statement: In the mass production of product labels, ensuring that the printed human-readable text (OCR) matches the machine-readable barcode is critical. Manual inspection on high-speed reel-to-reel machines is impossible, leading to risks of mixed data, missing prints, or unreadable codes reaching the end customer. The Challenge: The client needed a system capable of inspecting every single label on a moving roll. The challenge involved not just reading the data, but performing a Dual Validation Cross-check—verifying that the alphanumeric string (OCR) perfectly matches the decoded Barcode data in real-time, while also controlling the machine’s motor to stop immediately upon detecting a defect. ...

Digitalizing Quality Control Data Problem Statement: Manual data recording in high-speed manufacturing is prone to “Human Error” and creates “Data Silos.” At ETON INDUSTRY, operators had to manually write down critical parameters (Weight, Thickness, Length) for every finished product, leading to delayed reporting and inaccurate traceability. The Challenge: The system needed to interface directly with the existing machine’s PLC to capture data exactly when the process finishes, without disrupting the operator’s workflow. It also required a robust “Target Counter” to alert operators when a specific order quantity was met. ...

Auto Transfer Laser Mark System Problem Statement: In a high-precision machining line, operators were manually transferring production data files from CNC machines to Laser Markers. This manual process, involving walking with USB drives or hand-keying serial numbers, created a bottleneck and introduced a high risk of “Human Error”—resulting in mislabeled parts and traceability issues. The Challenge: The core challenge was Cross-Platform Integration. We needed to bridge “Islands of Automation” that spoke different languages: ...

Digitalization of Batch Process in Rubber Industry Problem Statement: In traditional rubber mixing, reliance on standalone PLCs often limits the complexity of recipe management and data storage. The client needed to upgrade a Banbury Mixer 75L to handle complex step sequences based on Time and Temperature, while ensuring 100% data traceability for quality assurance (QA). The Challenge: The project required high-level interoperability. We had to centralize data from diverse legacy devices speaking different protocols (Ishida Scales, Delta Temperature Controllers, Ammeters) into a single control interface, all while maintaining millisecond-level stability for motor control. ...

Visualizing Invisible Energy Costs Problem Statement: In large-scale manufacturing, electricity bills are a major operating cost, yet they often remain a “Black Box.” Factory managers struggle with manual meter readings, lack of real-time visibility into power consumption trends, and inability to correlate energy spikes with specific production processes. The Challenge: The client needed a centralized system to collect data from multiple Digital Multimeters distributed across the factory. The system had to handle high-frequency data (Voltage, Current, Power, THD), process it for cost analysis, and present it on a responsive web dashboard accessible from anywhere. ...

Mass Production Aging Test System Problem Statement: The client required a mass production testing facility for MXR100030 (30kW) and MXR100050 (50kW) charging modules. The scale involves testing 20 units simultaneously per workstation. The Challenge: The 10-Second Deadline The most critical engineering constraint is the module’s internal Watchdog Timer. If a module does not receive a valid communication packet within 10 seconds, it automatically cuts off the DC power output. With 20 devices flooding the bus with telemetry data, network congestion could easily cause a “Heartbeat Miss,” leading to a failed test and production downtime. Our Solution: High-Throughput CAN Architecture We designed a Multi-Threaded Control Application capable of handling high-density traffic without latency. We moved away from a single daisy-chain loop to a Tree Topology using USB-CAN Hubs to distribute the bandwidth load. ...

High-Precision Sliding Tester Control System Problem Statement: The client, a leading automotive parts manufacturer, relied on a manual or semi-manual process for endurance testing (cyclic motion) of their products. The existing control software was built on legacy technology (WinForms), making it difficult to maintain, prone to human error in parameter settings, and lacked the flexibility to adapt to new hardware sensors. The Challenge: Human Variation: Manual setups led to inconsistent test results (speed, acceleration, cycle counts). Legacy Debt: The old codebase was tightly coupled with specific hardware drivers, meaning replacing a broken motor or sensor required a complete software rewrite. Reliability: The system needed to run thousands of cycles continuously without crashing or losing data. Our Solution: Clean Architecture for Industrial QC We re-engineered the entire control system using Modern C# (WPF) and adopted Clean Architecture principles. The focus shifted from simple “control” to creating a robust “platform” for quality assurance. ...

Project Overview Problem Statement: In high-precision manufacturing, Quality Control (QC) relied on manual data recording from Linear Scales. This led to human errors (typos), lack of traceability, and slow reporting. Furthermore, the client used a massive Excel template filled with complex statistical formulas (CPK, Histogram) to generate reports. The Challenge: The critical technical bottleneck was the Excel Report Generation. Standard libraries (like Interop or standard OpenXML wrappers) failed or crashed because the client’s template file was too large and complex. Opening the file to write data programmatically caused memory overflows and corrupted the complex formulas embedded in the file. ...