The task
In modern production environments, data is generated in many places at the same time. Machine control systems supply process values every millisecond, ERP systems manage order and material data, and quality assurance records measured values and camera images of each product. However, this data usually exists in isolation from each other in separate systems without a common time reference and without a standardized interface.
The challenge
Heterogeneous data sources with different protocols, cycle times and formats are difficult to synchronize. Image data from quality assurance is particularly data-intensive and is rarely linked to machine status data. Cloud-based solutions cause latency and bandwidth costs. A complete process analysis across all systems remains an unsolved problem in many companies.
The solution
EdgeBrain handles local data fusion in real time. It receives process values directly from machine controllers via OPC UA, MQTT or Modbus/TCP, simultaneously reads order data from the ERP system and links both with measured values and image data from quality assurance. All data streams are provided with a common time stamp and merged into a uniform process image. This creates a complete digital fingerprint of every production process on site, without a cloud connection.
Key technical data
| Parameter |
Value |
| Machine data |
OPC UA, MQTT, Modbus/TCP |
| ERP connection |
REST-API, OPC UA, database connection |
| Quality assurance |
Camera integration, data acquisition |
| Image processing |
Locally on EdgeBrain, no cloud upload required |
| Data synchronization |
Real-time time stamping of all sources |
| Storage |
Local, optional transfer to higher-level systems |
The added value
EdgeBrain’s data fusion gives production managers a complete view of the entire process for the first time. Quality problems can be correlated directly with machine statuses and order data. Traceability is raised to a new level: A seamless log of process parameters, measured quality values and the corresponding camera image is available for every manufactured part.
