Non-Intrusive Data Collection for Legacy Gearset Testing (Oerlikon T60)
Gearset Matching Data Collection System Problem Statement: A Tier-1 automotive manufacturer in Pluak Daeng, Rayong, faced a traceability challenge with their Oerlikon T60 (Bevel Gear Testing) machines. The machine performs critical matching tests for Ring and Pinion gears, but the test results were stored locally in proprietary text files. The Challenge: Closed System: The machine runs on legacy software. Modifying the internal code to send data to a database was deemed too risky and would void the manufacturer’s warranty. Data Silo: Quality engineers had to manually check files, leading to data gaps and lack of real-time traceability in the central ERP/MES. Our Solution: The “Sidecar” Integration Pattern We implemented a Non-Intrusive Data Collection System. Instead of hacking the machine’s software, we treated the machine as a “Black Box” and monitored its outputs externally. ...