Omron Electronics Iberia S.A.U. is the Spanish subsidiary of OMRON Corporation. Its Robotics Division, based in Madrid, provides hardware, software and engineering solutions for industrial automation and robotics in a range of industries, including the automotive and healthcare sectors. In the factory of one of Omron's customers, an existing production line was to be extended with autonomous mobile robots (AMRs) while operations continued.
To coordinate the systems involved, XITASO developed middleware tailored specifically to the project. It translates, coordinates and monitors the data of all connected systems and fits into the existing production environment. XITASO is thus responsible for the technical connection layer between the AMRs, the controllers and the other third-party systems on the line.
The challenge: integrating AMRs into a line of heterogeneous third-party systems without downtime
The biggest challenge was not the AMRs themselves but integrating the existing third-party systems with their different technology stacks. To extend the existing line with AMRs, these systems had to work together reliably.
This resulted in several requirements at once:
- The AMRs had to be integrated into a production line that was already running, without interrupting operations for longer than necessary – downtime had to be kept to a minimum.
- The systems involved are based on different technology stacks and still have to work together reliably.
- Communication between the components has to take place in real time so that the processes on the line stay in sync.
- Operator safety must be ensured at all times.
On top of this came a very tight schedule. Together with the technical complexity – several systems, different stacks, ongoing operations – the implementation called for specialist expertise.
The solution: middleware as a translation and coordination layer – processed locally and visible in a dashboard
XITASO developed middleware that acts as a central layer between the systems involved. It receives data from the AMRs, the controllers (PLCs) and the other third-party systems, translates it between the different technology stacks and uses it to coordinate the processes on the line. This allows systems with different technology stacks to work together.
Technically, the middleware is based on C#, Kafka and MQTT, among other technologies; the application has an event-driven architecture. The machines are connected via PLC communication. Modbus was also used to communicate with a hardware-level controller: this connected a system that reports in real time whether the AMRs are allowed to enter and move within safety-critical areas of the factory.
Most of the data is not stored but processed directly to derive decisions and pass them on to the systems involved. Data processing therefore remains on site in the production environment. A user interface shows the current status of the connected AMRs and other components, making the interaction between the systems visible during operation.
XITASO worked closely with Omron's lead engineers and took an agile, iterative approach: requirements that only emerged while analysing the production line were continuously incorporated. The XITASO team was on site to support the factory acceptance tests (FAT) and to optimise the runtime behaviour of the middleware.
The result: coordinated real-time operation and a reusable platform for further AMR projects
With XITASO's middleware, the AMRs and the existing third-party systems on the line work together, even though they are based on different technologies. Processes are coordinated in real time, and the status of the connected components is visible in the user interface. In concrete terms for operations: the AMRs were integrated into the running production line without interrupting operations for longer than necessary, processes stay in sync in real time and operator safety is maintained.
The software developed outperformed the previously used solution and improved several existing functions. Despite the tight schedule, which initially made on-time completion seem unlikely, the project goal was achieved.
Beyond this specific application, XITASO's solution provides a modular and reusable platform. Omron can use it as the basis for further advanced projects with autonomous mobile robots.
„Thanks to the many hours XITASO invested in this project, we were able to reach our goal even though on-time completion initially seemed unlikely. The quality of the software developed far exceeded expectations."
– Robotics FAE Manager, Omron Electronics Iberia S.A.U.
