OP10-CNC Rough Machining
The first station in the production line performs rough machining operations on raw aluminum castings. This 5-axis CNC removes bulk material and creates the primary geometry of the brake caliper housing. Use Modbus TCP to read real-time machine state, production counters, sensor data, and fault information.
localhost:5020
Unit ID:
1
Update Rate:
50ms (20 Hz)
Business Purpose
Why Connect to This Simulator?
OEE Monitoring: Read production counters (good/bad parts) and machine states to calculate availability, performance, and quality metrics.
Predictive Maintenance: Monitor spindle load, vibration, and temperature sensors to detect wear patterns before failures occur.
Energy Management: Track power consumption per part for energy cost allocation and efficiency optimization.
Downtime Analysis: Capture fault codes and state transitions to build Pareto charts of downtime causes.
Station Specifications
Modbus Register Map
All registers are holding registers (function code 03). Addresses follow Modbus convention (40001 = register 0).
| Address | Name | Type | Description |
|---|---|---|---|
40001 | State | uint16 | 0=OFF, 1=IDLE, 2=RUNNING, 3=FAULTED, 4=BLOCKED, 5=STARVED |
40002 | Step | uint16 | 0=IDLE, 1=LOADING, 2=PROCESSING, 3=UNLOADING |
40005 | PartsProduced | uint16 | Cumulative parts count |
40006 | PartsGood | uint16 | Good parts count |
40007 | PartsBad | uint16 | Bad parts (scrap + rework) |
40008 | FaultActive | uint16 | 0=No fault, 1=Fault active |
40009 | FaultCode | uint16 | 1001=Spindle Overload, 1002=Tool Break, 1003=Coolant Low |
40010 | SpindleSpeed | uint16 | RPM (0-12000) |
40011 | SpindleLoad | uint16 | Load % x10 (45.2% = 452) |
40015 | Vibration | uint16 | mm/s x1000 (0.5 = 500) |
40016 | Temperature | uint16 | Celsius x10 (35.2 = 352) |
40022 | PowerKW | uint16 | kW x100 (15.5 = 1550) |
40110-11 | RunTime | uint32 | Accumulated run time (seconds) |
40112-13 | DownTime | uint32 | Accumulated down time (seconds) |
OP30-WASH Parts Washer
The parts washer uses high-pressure aqueous cleaning to remove machining chips, coolant residue, and contaminants from the brake caliper housing. Clean parts are essential for accurate leak testing at the next station. Monitor wash temperature, pressure, and filter status to ensure cleaning quality.
localhost:5021
Unit ID:
1
Update Rate:
50ms (20 Hz)
Business Purpose
Why Connect to This Simulator?
Quality Correlation: Monitor wash temperature and pressure to correlate cleaning parameters with downstream leak test results.
Maintenance Scheduling: Track filter pressure differential to schedule filter replacements before clogging causes downtime.
Process Optimization: Analyze cycle times and temperature profiles to optimize cleaning without affecting quality.
Environmental Compliance: Log water usage and chemical consumption for sustainability reporting.
Station Specifications
Modbus Register Map
| Address | Name | Type | Description |
|---|---|---|---|
40001 | State | uint16 | 0=OFF, 1=IDLE, 2=RUNNING, 3=FAULTED, 4=BLOCKED, 5=STARVED |
40002 | Step | uint16 | 0=IDLE, 1=LOADING, 2=WASHING, 3=UNLOADING |
40005 | PartsProduced | uint16 | Cumulative parts washed |
40006 | PartsGood | uint16 | Successfully cleaned parts |
40007 | PartsBad | uint16 | Parts requiring re-wash |
40008 | FaultActive | uint16 | 0=No fault, 1=Fault active |
40009 | FaultCode | uint16 | 3001=Temp Low, 3002=Filter Clogged |
40013 | WashPressure | uint16 | bar x10 (6.5 = 65) |
40014 | WashTemp | uint16 | Celsius x10 (55.0 = 550) |
40022 | PowerKW | uint16 | kW x100 |
OP20-CNC Finish Machining
The finish machining station performs precision operations to achieve final dimensions and surface quality. This station is critical for bore tolerances and thread quality. OPC UA provides a rich, hierarchical data structure with strong typing and metadata for enterprise integration.
opc.tcp://localhost:4840
Security:
None (Anonymous)
Business Purpose
Why Connect to This Simulator?
Precision Monitoring: Track bore diameter measurements and surface finish parameters for SPC analysis.
Tool Life Management: Monitor tool wear counters to optimize tool change intervals and reduce scrap from worn tools.
Traceability: Capture part serial numbers with timestamps for full genealogy tracking through the production line.
Enterprise Integration: OPC UA's standardized information model enables seamless connection to MES and ERP systems.
Station Specifications
OPC UA Node Structure
Nodes are organized under namespace index 1. Browse from ns=1;s=OP20-CNC
| Node ID | Type | Description |
|---|---|---|
ns=1;s=OP20-CNC.State | String | IDLE, RUNNING, FAULTED, BLOCKED, STARVED |
ns=1;s=OP20-CNC.Step | String | IDLE, LOADING, PROCESSING, UNLOADING |
ns=1;s=OP20-CNC.CurrentPart | String | Serial number of part being processed |
ns=1;s=OP20-CNC.Counters.PartsProduced | Int64 | Total parts completed |
ns=1;s=OP20-CNC.Counters.PartsGood | Int64 | Good parts count |
ns=1;s=OP20-CNC.Counters.PartsBad | Int64 | Scrap + rework count |
ns=1;s=OP20-CNC.Sensors.SpindleSpeed | Float64 | Current spindle RPM |
ns=1;s=OP20-CNC.Sensors.SpindleLoad | Float64 | Spindle load percentage |
ns=1;s=OP20-CNC.Sensors.Temperature | Float64 | Machine temperature (Celsius) |
ns=1;s=OP20-CNC.Energy.PowerKW | Float64 | Current power consumption (kW) |
ns=1;s=OP20-CNC.Energy.EnergyKWH | Float64 | Cumulative energy (kWh) |
ns=1;s=OP20-CNC.Tool.LifeCount | Int32 | Current tool usage count |
ns=1;s=OP20-CNC.Tool.LifeRemaining | Int32 | Remaining tool life |
ns=1;s=OP20-CNC.Fault.Active | Boolean | True if fault is active |
ns=1;s=OP20-CNC.Fault.Code | String | E2001=Bore OOS, E2002=Tap Break |
ns=1;s=OP20-CNC.Time.RunTimeSec | Float64 | Accumulated run time |
ns=1;s=OP20-CNC.Time.DownTimeSec | Float64 | Accumulated down time |
OP40-TEST Leak Test
The final quality gate uses pressure decay testing to verify hydraulic integrity of the brake caliper. Parts are pressurized and held while monitoring for pressure drop. This station determines if parts pass to finished goods or are rejected. Critical for safety-related automotive components.
opc.tcp://localhost:4841
Security:
None (Anonymous)
Business Purpose
Why Connect to This Simulator?
Quality Assurance: Every part's leak test result determines final pass/fail status - essential for quality KPIs.
Defect Root Cause: Correlate leak failures with upstream machining parameters to identify process issues.
Compliance Documentation: Automotive safety regulations require traceable test records for every brake component.
Yield Analysis: Monitor first-pass yield trends to detect quality drift before it impacts production targets.
Station Specifications
OPC UA Node Structure
Nodes are organized under namespace index 1. Browse from ns=1;s=OP40-TEST. Test-specific sensors provide leak rate and pressure decay measurements.
| Node ID | Type | Description |
|---|---|---|
ns=1;s=OP40-TEST.State | String | Machine state |
ns=1;s=OP40-TEST.Step | String | IDLE, LOADING, PRESSURIZING, TESTING, UNLOADING |
ns=1;s=OP40-TEST.CurrentPart | String | Part serial number under test |
ns=1;s=OP40-TEST.Counters.PartsProduced | Int64 | Total parts tested |
ns=1;s=OP40-TEST.Counters.PartsGood | Int64 | Parts passed leak test |
ns=1;s=OP40-TEST.Counters.PartsBad | Int64 | Parts failed leak test |
ns=1;s=OP40-TEST.Sensors.TestPressure | Float64 | Current test pressure (bar) |
ns=1;s=OP40-TEST.Sensors.LeakRate | Float64 | Measured leak rate (cc/min) |
ns=1;s=OP40-TEST.Sensors.PressureDecay | Float64 | Pressure drop during test (mbar) |
ns=1;s=OP40-TEST.Fault.Active | Boolean | Fault status |
ns=1;s=OP40-TEST.Fault.Code | String | E4001=Air Pressure Low, E4002=Seal Wear |
MES REST API
The MES API provides production execution and shop floor control capabilities. Manage work orders, track production records with full part traceability, monitor quality measurements, record downtime events, and access real-time equipment status. All data is JSON-formatted for easy integration.
http://localhost:8080/api/v1
Business Purpose
Why Connect to This Simulator?
Analytics Platform Integration: Structured JSON responses designed for BI tools and data warehouses.
OEE Calculation: Production counters, downtime events, and quality records provide all inputs for OEE metrics.
Part Traceability: Every part's complete production history including cycle times, measurements, and tool usage.
Master Data Sync: Equipment definitions, product routings, and reason codes for maintaining data consistency.
Available Endpoints
Master Data
Work Orders
Production Data
Quality & Downtime
Real-Time Status
ERP REST API
The ERP API provides business-level data for inventory management and stock movements. Use this API to simulate material replenishment, finished goods shipping, and inventory tracking operations that typically come from enterprise resource planning systems.
http://localhost:8081/api/v1
Business Purpose
Why Connect to This Simulator?
Inventory Visibility: Real-time stock levels for raw materials, WIP, and finished goods.
Material Flow: Track stock movements from receiving through production to shipping.
Automation Control: Configure automatic material replenishment and shipping rules.