ControllerMES

Customer: Ergodesign

Version: 1.0

Author: Ivan Michalev Page 1 / 46 17/07/2023

Content

1 General ................................................................................................................................... 4
1.1 Terms and definitions ...................................................................................................... 4
1.2 Components Typification ................................................................................................. 5
1.2.1 Component geometry .................................................................................................. 5
1.2.2 Component flank ......................................................................................................... 5
1.2.3 Component edge ......................................................................................................... 5
1.2.4 Component description ................................................................................................ 6
1 Material Flow ........................................................................................................................... 7
1.1 Overview ......................................................................................................................... 8
A – Material Supply...................................................................................................... 9
B1 – Storage and retrieval system ............................................................................... 9
B2 – Manual offcut storage .......................................................................................... 9
C – Lot generation ControllerMES ............................................................................. 10
D – Nesting - CENTATEQ-N...................................................................................... 10
E – Panel Dividing - HPP ........................................................................................... 10
G –Sorting ................................................................................................................. 10
2 Communication with external systems .................................................................................. 11
2.1 Communication from iX to MES ..................................................................................... 11
2.1.1 Principles ................................................................................................................... 11
2.1.2 MPR Generation ........................................................................................................ 12
3 Communication with production ............................................................................................ 13
3.1 MES to CutRite .............................................................................................................. 13
3.1.1 Part list – rectangular parts (HPP and NES) .............................................................. 13
3.1.2 BDX ........................................................................................................................... 15
3.1.3 PTX ........................................................................................................................... 16
3.1.4 Archive ...................................................................................................................... 16
3.1.5 Part list – nonrectangular parts (NES)........................................................................ 16
3.1.6 BDX ........................................................................................................................... 18
3.1.7 PTX ........................................................................................................................... 18
3.1.8 Archive ...................................................................................................................... 18
3.2 Labeling and identification ............................................................................................. 19
3.3 MES to Nesting.............................................................................................................. 19
3.3.1 MES to CENTATEQ .................................................................................................. 19
3.3.2 CENTATEQ to MES .................................................................................................. 19
4 IT infrastructure ..................................................................................................................... 20
4.1 Server............................................................................................................................ 20
4.1.1 MES application server .............................................................................................. 20
4.1.2 MES application test server ....................................................................................... 20
4.1.3 MES database server ................................................................................................ 20
4.1.4 MES database test server.......................................................................................... 20
4.2 Databases ..................................................................................................................... 21
4.2.1 MES database PROD ................................................................................................ 21
4.2.2 MES database DEV ................................................................................................... 21
4.2.3 ERP database ........................................................................................................... 21
4.2.4 CENTATEQ database ............................................................................................... 22
4.3 MES Folder structure ..................................................................................................... 22
4.4 ERP File server ............................................................................................................. 22

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ControllerMES
Customer: Ergodesign

Version: 1.0

Author: Ivan Michalev Page 2 / 46 17/07/2023

5 CMES Functionality ............................................................................................................... 23

5.1 Lot generation ............................................................................................................... 23
5.1.1 Generation of production lots / optimization ............................................................... 23
5.1.1.1 Work process ..................................................................................................... 23
5.2 Ignore Cnc oversize ....................................................................................................... 24
6 ControllerMES implementation .............................................................................................. 25
6.1 Client installation ........................................................................................................... 25
6.2 Production Routes ......................................................................................................... 25
6.3 Data completion............................................................................................................. 25
6.3.1 Route determination (WCC) ....................................................................................... 25
6.3.2 Working places .......................................................................................................... 27
6.3.3 Production routes ...................................................................................................... 28
6.3.4 Workstation Assignment ............................................................................................ 28
6.3.5 Cutting workstation .................................................................................................... 29
6.3.6 Edge data from Geoform (WCC)................................................................................ 29
6.4 Edge data generation .................................................................................................... 31
6.5 Lot generation ............................................................................................................... 32
6.5.1 Calculate Cutting Dimension ...................................................................................... 32
6.5.2 Optimization rectangular parts ................................................................................... 32
6.5.2.1 Configuration ..................................................................................................... 33
6.5.2.2 Scripts for the custom CutRiteWrapper via external DB ..................................... 37
6.5.3 Optimization shaped parts ......................................................................................... 37
6.5.3.1 Configuration ..................................................................................................... 38
6.5.4 Delete optimization .................................................................................................... 42
6.6 Server Programms ........................................................................................................ 42
6.6.1 Export bracket ........................................................................................................... 43
6.7 Feedback configuration ................................................................................................. 43
6.8 Configuration IgnoreCncOversize .................................................................................. 43
1.2 Data reorganization ....................................................................................................... 44
Reorganization of database tables............................................................................. 45
7 Lessons Learned................................................................................................................... 46

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Author: Ivan Michalev Page 3 / 46 17/07/2023

1. History
Date Description Author
04/07/2023 Creation Ivan Michalev
14/07/2023 Described the lot generation configuration Ivan Michalev

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1 General

1.1 Terms and definitions

In the document there are used several terms and definitions.

- Production order

A production order identifies the group of physical identical parts which must be produced
with the same data.
The quantity of a production order can be 1 or greater than one.
If the part must be produced the next time, it is produced with another production order and
can have a different production quantity.

Production orders do not only exist for the part production area but also for assembly,
packaging and loading areas.

- Part number

The part number identifies the physical part which is produced.

A production order refers always to 1 part number (with a quantity of 1 or more than one).

- Product number

The equivalent to the part number is the product number in the assembly area.
A production order refers also always to 1 product number (with a quantity of 1 or more
than one).

- Unique part identifier (UPI)

The unique part identifier is the “name” of a part. With this identifier exactly 1 piece can be
found. Also, if there exist parts which are physical identical, no matter if they have the same
or different production orders, they must have different unique part identifiers.
In MES this is also known as item number

- Unique furniture identifier (UFI)

The unique furniture identifier is the “name” of a product. With this identifier exactly 1
furniture can be found. Also, if there exists furniture which are physical identical, no matter
if they have the same or different production orders, they must have different unique
furniture identifiers.

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- Customer order position

A customer order position is part of a customer order and describes one product. The
quantity for the position can be 1 or greater than one.

A customer order position refers to a production order for a product.

- Customer order

A customer order consists of one or more customer order positions.

1.2 Components Typification

The following descriptions and terms are used for part typing:

- Component geometry
- Component flank
- Component edge

1.2.1 Component geometry

• Describes the geometric basic form of a component.

1.2.2 Component flank

• Describes one side of the component with the following characteristics.

▪ Description flank
▪ Edge ID
▪ Edge material (MEL, ABS, PP, etc.)
▪ Glue type (EVA, PUR, Laser)
Edge length
▪ Edge length
▪ Edge height Profile top

▪ Edge thickness
Edge heigth

▪ Description profile
▪ Profile of the edge per edge
Profile below
▪ Transition edge to surface
Thickness
▪

1.2.3 Component edge

• Describes all corners of a component with the following characteristics.

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▪ Description transition
▪ Edge transition per edge
▪ Profile at the edge

Edge transition

1.2.4 Component description

• The imos iX provides a sufficient component description for each production order.

▪ Minimal description for the cutting process

▪ Component Structure
▪ Material ID
Thickness

▪ Structure of the surface Material ID

▪ Finished-length
▪ Finished -width
▪ Finished -thickness Finished length

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1 Material Flow

MES Terminal
MES Terminal

Customer system not in the

Automatic Transport Automatic printer
project scope

Machining system Manual Transport Manual printer

Contol scanner
Manual system Automatic in or out feed

Manual scanner
Manual in or out feed
Pick by light

Material flow crossover

Pile / Stack

Trolley

10
1
2
3

8
9
5
4

7
6

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1.1 Overview
Warehouse

Packaging Assembly

Manual scanner

D Manual printer
G

Nesting Sorting

Automatic printer

Raw boards
A B1 B2
Raw boards
Automatic offcuts
Manual offcut
Storage and Retrieval System Storage
C Rectangular parts

Manual
offcuts
Automatic
E
<

offcuts

HPP Edgebander BHX500

Manual printer Manual scanner Manual scanner

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A – Material Supply

The raw material is delivered manually to the storage by forklift.

No MES functionality is necessary for this operation.

[Cell Function]
The storage and retrieval system is managed by the cell control.

Stacks of raw boards will be placed at the infeed station.

There they will be manually introduced to the system through the standard storage management.
The cell control will independently transport and manage the raw boards.

B1 – Storage and retrieval system

The storage and retrieval system contains homogeneous and/or chaotic stacks of material.
The stock can be retrieved from the storage management system.
The HPP saw and the nesting machine are fed by the cell control system with a prestored
package.
Basically, any material can be present in the storage system.
The material provision from the horizontal storage is organized automatically by the cell
control.
Part labels will be applied on the raw board before cutting.

[Cell Function]
The cell control reads the material request and organizes the material supply to the saw and the
nesting.
The cell control provides an "inventory query".
This is necessary to feed the optimization with the correct material stock.
The cell control provides ControllerMES with "standard retrieval reports".

The labeling of the parts is done by the cell control of the storage system.

B2 – Manual offcut storage

Manual offcuts are stored manually in a customer-side manual offcut storage.

The manual offcut storage is managed as an external storage in the library of the
storage management system.
Manual offcuts can only be used for the next optimization in ControllerMES when they are
physically available in the storage system.
Manual offcuts that are used in an optimization run are blocked in the storage management
system.
Manual offcuts must be brought to the saw manually.

[Cell Function]
The cell control reads the material request and organizes the material supply to the saw.
The material supply from the manual offcut storage must be carried out manually; the cell
control system provides information for this in digital form.

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C – Lot generation ControllerMES

In the lot generation of ControllerMES the operator creates production lots manually.
After a lot is completed ControllerMES transfers two PNX files to CutRite, one for the HPP
and one for the nesting machine. The final decision for the workplace is done manually in
CutRite.

D – Nesting - CENTATEQ-N

The nesting machine always works on one optimization batch.

All parts are automatically labeled individually by the storage system.

All offcuts are manually removed and labelled with a manual printer on the outfeed of the
machine.

The use of automatic offcuts is only permitted if these offcuts are available and physically
present in the storage and retrieval system before an optimization is carried out.
Manual offcuts will not be used in the nesting process.

The unique part ID is used as the barcode, which uniquely identifies the part.

At the machine outfeed all nested parts will be manually removed, sorted, and transported
to the next workstation without data support of ControllerMES.

[Cell Function]
The storage and retrieval system transfers a run and a plan (nest) to the machine for each panel.

The nesting cell provides feedback for each part, based on the UniquePartId in a SQL Database
table as it is assumed in the HOMAG standard.
The cell must differentiate between drilling feedback and nesting feedback.
Entries of already manufactured parts are cyclically deleted by the cell control.

E – Panel Dividing - HPP

The HPP saw is already integrated in ControllerMES.

This process will stay the same and there are no further requirements.

G –Sorting

Finished components from the nesting or the BHX are manually stacked or sorted into
transport containers and moved manually to the next workstation without data support of
ControllerMES.

[Cell Function]
No cell control available.

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2 Communication with external systems

2.1 Communication from iX to MES
2.1.1 Principles

• For the communication between ERP and MES, the standard interface
HG_Interface_1.5.006 is being used.

• The SQL table is hierarchical, with the following levels of hierarchy:

- Article
- Subassembly
- Part
- Core material
- Surface top
- Surface bottom
- Edges
- Connectors
- CAM-Data
- Groove data

To display this hierarchy, the following table elements are obligatory:

Table element Description

RecordMode Action mode:

Insert / Update = 1
Delete = 2
ID Contains a unique identifier for the dataset in the order.
PARENTID Contains a unique identifier for the dataset for next higher level in
the hierarchy, which includes the dataset
ORDERID Order number from HOMAG iX
TYP The type of the hierarchy level
PartType Specification of the parts
Mainline Article Position number
DesiredTargetQuantity Quantity
TransferState Writing system with insert = 0
Writing system when finished = 10
Reading system during processing = 15
Reading system error-free after processing = 20
Reading system faulty after processing = 99
TransferDate Time stamp of the last action

The hierarchy within an order is mapped through the fields TYP, ID and PARENTID. The field TYP
contains the hierarchy level. Typical values are:
Code number Meaning Description

1 Article An article includes n subassemblies

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2 Subassembly A subassembly includes n parts and n

connectors. The subassembly of a MPE child
part is the mother part. The subassembly of a
drawer part is the drawer. Apart from that, to
each part is assigned a unique subassembly
3 Part A core material, the surface top, surface bottom
and n edges belong to a part.
4 Core material Contains information about the used core
material
5 Surface top Contains Information about the surface top
6 Surface bottom Contains Information about the surface bot
7 Edges The edge properties are described here
8 Connector Contains information about the used connectors
9 CAM-Data Contains information about the PXM data
10 Groove data Groove information for the edgebanding
machine

2.1.2 MPR Generation

• Imos iX generates .mpr files for following machines:

o BHX055
o BHX500
o CENTATEQ_N210 – scope of the current project

• The mpr files are stored in the standard “imorder”-folder structure from imos on an ERP
file server (172.16.0.63)

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3 Communication with production

3.1 MES to CutRite

• At the end of the batch-sizing process the MES creates a text-file MES.

• The cutting list files are stored on the MES Server.

• The MES sets all ProductionItems automatically to status “optimized” after the batch sizing
process.

• We adopt the same definition of a part list for rectangular parts produced on the HPP and
the NES (Nesting ) workplaces

• Parts with non-rectangular shape are only produced on NES (Nesting workplace) which
adopts the same cutting list file structure with added path to the nesting file location.

• The optimization runs in manual mode.

3.1.1 Part list – rectangular parts (HPP and NES)

• Line 1: Title for part list

Name of the optimization run

• Line 2: Optimizing parameter

Name of optimizing parameter list HPP: Ergodesign_Vasko
Name of optimizing parameter list NES: Rectangle

• Line 3: Saw parameter

Name of saw parameter list HPP: HPP300_HOMAG
Name of saw parameter list NES: NotInUse

• Line 4 and following: List of parts

N° Fieldname General Length Data Note Example

cMES type
1 ProductionItem Reference 32 Char Unique Part ID 1234567890
Code N° (printed as Barcode)
2 Material Material code 64 Char Board material from 19_MEL_OAK
optimizer
3 CuttingLength Raw length 4.1 Float Cutting size for 2498.6
optimization
4 CuttingWidth Raw width 4.1 Float Cutting size for 1058.6
optimization
5 DesiredTargetQ Quantity 8 Integer 1
uantity
6 DesiredTargetQ Over 8 Integer Overproduction in 0
uantityMAX quantity
7 DesiredTargetQ Under 8 Integer Underproduction in 0
uantityMIN quantity

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N° Fieldname General Length Data Note Example

cMES type
8 GrainID Grain 1 Integer Grain direction 1
0 = No grain direction
1 = Grain in length
direction
9 PartName Add Info1 255 Char Name from wCC Side panel
Manufacturing
information
10 ProductionRout Add Info2 255 Char Production route CU1_EB1_DR1_FA
e 1
11 Not in use Add Info3 255 Char Reserved space
12 Not in use Add Info4 255 Char Reserved space
13 Not in use Add Info5 255 Char Reserved space
14 LabelInfo Add Info6 255 Char Partname for label Left side panel
15 GeoForm Add Info7 255 Char GeoForm from wCC Geo01
16 FinishSize Add Info8 255 Char Finished dimension 300 x 600 x 19
(Length x Width
x Thickness)
17 EdgeTransition Add Info9 255 Char Edgetransition, drawing 011:000:011:000
generated by CADMatic
18 Edge South Add Info10 255 Char Edge South (CADMatic 1 mm OAK
definition)
19 Edge North Add Info11 255 Char Edge North (CADMatic 1 mm OAK
definition)
20 Edge West Add Info12 255 Char Edge West (CADMatic 2 mm OAK
definition)
21 Edge East Add Info13 255 Char Edge East (CADMatic 1 mm OAK
definition)
22 OptimizationCod Add Info14 255 Char Optimization lot 0519-01
e
23 CustomerOrder Add Info15 255 Char wCC Order 1704123
Code
24 Customer Add Info16 255 Char Customer Max Mustermann
25 ArticlePosimos Add Info17 255 Char Combine wCC article Pos.01 H60-240
position and wCC article
26 DeliveryDate Add Info18 255 Char Lieferdatum 31.05.2017
27 Order date Add Info19 255 Char Order date 28.05.2017
28 LabelInfoAndNc Add Info20 255 Char Part name form Wcc Side Panel 5003
Program and NC program
number
29 NCSTOP Add Info21 255 Char NC Stop information as NCSTOP
text
30 ProductionOrder Add Info22 255 Char Production order and 1008513_1
AndQty quantity
31 Not in use Add Info23 255 Char Reserved space
32 ReproductionInf Add Info24 255 Char Displays the text Повторно
o “Повторно производство
производство” for
reproduction parts.
33 EdgebanderRef Add Info25 255 Char Orientation arrow LEFT
erenceEdge 1.Through feed
Edgebanding line.
Values: FRONT; BACK;
LEFT; RIGHT

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N° Fieldname General Length Data Note Example

cMES type
34 CncZeroLineBH Add Info26 255 Char Reserved space for cnc LEFT
X500 cero line for BHX500
Values: FRONT; BACK;
LEFT; RIGHT
35 EdgePassFront Add Info27 255 Char Edge pass front left 1/4
Left
36 EdgePassFront Add Info28 255 Char Edge pass front right 2
Right
37 EdgePassBackL Add Info29 255 Char Edge pass back left 5
eft
38 EdgePassBack Add Info30 255 Char Edge pass back right 3
Right
39 CncZeroLineBH Add Info31 255 Char Reserved space for cnc RIGHT
X055 cero line for BHX055
Values: FRONT; BACK;
LEFT; RIGHT

• Further definitions

o Format
- PNX

o Field separator
- Semicolon

o Decimal separator
- Point

o Output format
- UTF-8

o Decimal format
- num(4,2) 4 before comma, 1 decimal separator, 2 after comma

o Name of pnx file

- yyyymmdd-nnnn
(yyyy = year, mm = month, dd =day, nnnn = ascending sequence)

o Extension of pnx file

- pnx

o Path of pnx file HPP

- C:\ControllerMES_DATA\MESDataTransfer_DEV\MES_to_Cutrite\FLS\Impo
rt\HPP

o Path of pnx file NES

- C:\ControllerMES_DATA\MESDataTransfer_DEV\MES_to_Cutrite\FLS\Impo
rt\NEST

3.1.2 BDX

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• MES does not create board list file.

3.1.3 PTX

• MES does read PTX file.

3.1.4 Archive

• ControllerMES does not archive the cut list files

3.1.5 Part list – nonrectangular parts (NES)

• Line 1: Title for part list

Name of the optimization run

• Line 2: Optimizing parameter

Name of optimizing parameter list NES: Rectangle

• Line 3: Saw parameter

Name of saw parameter list NES: NotInUse

• Line 4 and following: List of parts

N° Fieldname General Length Data Note Example

cMES type
1 ProductionItem Reference 32 Char Unique Part ID 1234567890
Code N° (printed as Barcode)
2 Material Material code 64 Char Board material from 19_MEL_OAK
optimizer
3 CuttingLength Raw length 4.1 Float Cutting size for 2498.6
optimization
4 CuttingWidth Raw width 4.1 Float Cutting size for 1058.6
optimization
5 DesiredTargetQ Quantity 8 Integer 1
uantity
6 DesiredTargetQ Over 8 Integer Overproduction in 0
uantityMAX quantity
7 DesiredTargetQ Under 8 Integer Underproduction in 0
uantityMIN quantity
8 GrainID Grain 1 Integer Grain direction 1
0 = No grain direction
1 = Grain in length
direction
9 PartName Add Info1 255 Char Name from wCC Side panel
Manufacturing
information
10 ProductionRout Add Info2 255 Char Production route CU1_EB1_DR1_FA
e 1
11 Not in use Add Info3 255 Char Reserved space
12 Not in use Add Info4 255 Char Reserved space
13 Not in use Add Info5 255 Char Reserved space

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N° Fieldname General Length Data Note Example

cMES type
14 LabelInfo Add Info6 255 Char Partname for label Left side panel
15 GeoForm Add Info7 255 Char GeoForm from wCC Geo01
16 FinishSize Add Info8 255 Char Finished dimension 300 x 600 x 19
(Length x Width
x Thickness)
17 EdgeTransition Add Info9 255 Char Edgetransition, drawing 011:000:011:000
generated by CADMatic
18 Edge South Add Info10 255 Char Edge South (CADMatic 1 mm OAK
definition)
19 Edge North Add Info11 255 Char Edge North (CADMatic 1 mm OAK
definition)
20 Edge West Add Info12 255 Char Edge West (CADMatic 2 mm OAK
definition)
21 Edge East Add Info13 255 Char Edge East (CADMatic 1 mm OAK
definition)
22 OptimizationCod Add Info14 255 Char Optimization lot 0519-01
e
23 CustomerOrder Add Info15 255 Char wCC Order 1704123
Code
24 Customer Add Info16 255 Char Customer Max Mustermann
25 ArticlePosimos Add Info17 255 Char Combine wCC article Pos.01 H60-240
position and wCC article
26 DeliveryDate Add Info18 255 Char Lieferdatum 31.05.2017
27 Order date Add Info19 255 Char Order date 28.05.2017
28 LabelInfoAndNc Add Info20 255 Char Part name form Wcc Side Panel 5003
Program and NC program
number
29 NCSTOP Add Info21 255 Char NC Stop information as NCSTOP
text
30 ProductionOrder Add Info22 255 Char Production order and 1008513_1
AndQty quantity
31 Not in use Add Info23 255 Char Reserved space
32 ReproductionInf Add Info24 255 Char Displays the text Повторно
o “Повторно производство
производство” for
reproduction parts.
33 EdgebanderRef Add Info25 255 Char Orientation arrow LEFT
erenceEdge 1.Through feed
Edgebanding line.
Values: FRONT; BACK;
LEFT; RIGHT
34 CncZeroLineBH Add Info26 255 Char Reserved space for cnc LEFT
X500 cero line for BHX500
Values: FRONT; BACK;
LEFT; RIGHT
35 EdgePassFront Add Info27 255 Char Edge pass front left 1/4
Left
36 EdgePassFront Add Info28 255 Char Edge pass front right 2
Right
37 EdgePassBackL Add Info29 255 Char Edge pass back left 5
eft
38 EdgePassBack Add Info30 255 Char Edge pass back right 3
Right

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N° Fieldname General Length Data Note Example

cMES type
39 CncZeroLineBH Add Info31 255 Char Reserved space for cnc RIGHT
X055 cero line for BHX055
Values: FRONT; BACK;
LEFT; RIGHT
40 PathNestingFile Add Info32 255 Char Path to the dxf file C:\ControllerMES_
DATA\MESDataTra
nsfer_DEV\mes_to
_NEST

• Further definitions

o Format
- PNX

o Field separator
- Semicolon

o Decimal separator
- Point

o Output format
- UTF-8

o Decimal format
- num(4,2) 4 before comma, 1 decimal separator, 2 after comma

o Name of pnx file

- yyyymmdd-nnnn
(yyyy = year, mm = month, dd =day, nnnn = ascending sequence)

o Extension of pnx file

- pnx

o Path of pnx file NES

- C:\ControllerMES_DATA\MESDataTransfer_DEV\MES_to_Cutrite\FLS\Impo
rt\NEST_GEO

3.1.6 BDX

• MES does not create board list file.

3.1.7 PTX

• MES does read PTX file.

3.1.8 Archive

• ControllerMES does not archive the cut list files

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3.2 Labeling and identification

• Components are labelled individually.

• The label is printed and applied by the storage system before cutting.
• A barcode is printed on the label.
• The barcode represents the Unique-Part-ID.
This is mandatory in the HOMAG line in order to be able to ensure the operational reliability
of the system.
• To ensure the operational reliability of the system, a control scan of the label is performed
immediately after labeling.
• There is only one label design.
• ControllerMES provides the raw data for printing in the parts list (PNX) for optimization.
• The preparation for printing is the responsibility of the printing system.
ControllerMES does not generate ZPL strings.

3.3 MES to Nesting

3.3.1 MES to CENTATEQ

• DXF file destination as NES workplace

o C:\ControllerMES_DATA\MESDataTransfer_DEV\mes_to_NEST

• MES does not directly provide the DXF files to CENTATEQ, instead, CutRite imports
them and uses them in the optimization process.

• After optimization CutRite provides the “optimized” MPR to the machine control cell.

• All the required DXF files are created from the PXM Manager in imos iX.

3.3.2 CENTATEQ to MES

• Feedback SQL Database.

• Name of Database: HomagProcessData

• Name of table: MESFeedbackItems

Field Data Type Mandatory

Id bigint IDENTITY(1,1) NOT NULL
Reference nvarchar(200) NOT NULL
Machine nvarchar(80) NOT NUL
ReporterMachine int NOT NULL
ProductionStep int NOT NULL
QualityInfo int NOT NULL
Timestamp datetime2(7) NOT NULL
State int NOT NULL
CreationDate datetime2(7) NOT NULL
ModificationDate datetime2(7) NOT NULL

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4 IT infrastructure

4.1 Server

4.1.1 MES application server

• Name: MYCD-021
• IP: server-001.clusterdesktop.com:1924
• Domain: myclusterdesktop.com
• Operating System: Windows Server 2016 (64-Bit)
• Netmask: 255.255.0.0
• Gateway: 172.16.0.17
• DNS-Server: 172.16.0.1, 172.16.0.7

• User: MYCD-021\Administrator
• Password: *****KeePass****

• Remote access to server with via remote desktop

4.1.2 MES application test server

• Not implemented

4.1.3 MES database server

• Name: MYCD-023
• IP: server-001.clusterdesktop.com:1892
• Domain: myclusterdesktop.com
• Operating System: Windows Server 2022 (64-Bit)
• Netmask: 255.255.0.0
• Gateway: 172.16.0.17
• DNS-Server: 172.16.0.1, 172.16.0.7

• User: MYCD-023\Administrator
• Password: *****KeePass****

4.1.4 MES database test server

• Not implemented

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4.2 Databases

4.2.1 MES database PROD

• Servername: MYCD-023
• Server-IP: 172.16.0.23

• Product: Microsoft SQL Server Standard (64-bit)

• Version: 13.0.5103.6 (SQL Server 2016)
• Language: English (United States)
• Server Collation: SQL_Latin1_General_CP1_CI_AS

• Database Name: CMES_PROD

• User: cmes
• Password: ****KeePass****

4.2.2 MES database DEV

• Servername: MYCD-023
• Server-IP: 172.16.0.23

• Product: Microsoft SQL Server Standard (64-bit)

• Version: 13.0.5103.6 (SQL Server 2016)
• Language: English (United States)
• Server Collation: SQL_Latin1_General_CP1_CI_AS

• Database Name: CMES_DEV

• User: cmes
• Password: ****KeePass****

4.2.3 ERP database

• Servername: MYCD-023\MSSQLEXPED
• Server-IP: 172.16.0.63

• Product: Microsoft SQL Server Express (64-bit)

• Version: 13.0.5103.6 (SQL Server 2016)
• Language: English (United States)
• Server Collation: SQL_Latin1_General_CP1_CI_AS

• Database Name: ControllerMES_ERP_iX

• User: ed.4.ed.mes
• Password: ****KeePass****

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4.2.4 CENTATEQ database

• Servername:
• Server-IP:

• Product: Microsoft SQL Server Express Edition with Advanced Services

• Version: 10.0.5500.0 (SQL Server 2008 No SP)
• Language: English (United States)
• Server Collation: SQL_Latin1_General_CP1_CI_AS

• Database Name: HomagProcessData

• User: sa
• Password: Homag

4.3 MES Folder structure

• Servername: MYCD-023
• IP: 172.16.0.23

• Main Folder: C:\Homag\MESDataTransfer

• Archive Folder: C:\Homag\MESDataArchive

4.4 ERP File server

• Servername: DG-HOMAG-03
• IP: 192.168.178.39

• Main Folder: C:\ControllerMES_DATA\MESDataTransfer

• Archive Folder: C:\ControllerMES_DATA\MESDataTransfer_DEV

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5 CMES Functionality
5.1 Lot generation
5.1.1 Generation of production lots / optimization

Case1: Cutting rectangular parts on Nesting machine

• The production planner decides in CutRite if the cutting process is executed on the nesting
or on the cutting machine.
• ControllerMES provides two identical PNX files to CutRite for each optimization lot, one for
the Nesting and the other is for the current HPP.
• In this case no drillings are done on the nesting machine.

Case2: Use Nesting as nesting machine (Geo-Form-Processing)

• Nesting based on the DXF-file generated by imos. Only non-rectangular parts

(Geoform≠G01).
• Edgebanding process based on the ControllerMES edge data generation (no sizing
allowed, same process in the current Ergodesign installation)
• Using the dxf export to CutRite it is not possible for ControllerMES to recalculate the cutting
dimensions based on the edge information.
• In this case the customers CAD|CAM has to provide the correct cutting dimensions which
will be adopted by ControllerMES without checking for correctness.

5.1.1.1 Work process

• The operator selects the configuration based on the type of optimization case he wants to
carry out.

• The operator manually selects the production orders to assign them into one production lot.
• In the ControllerMES app lot generation, all production orders are displayed with the work
step cutting and the due date for production.
• The capacity view shows the HPP capacity.
• The graph shows the percentage of the used capacity relative to number of parts/day
defined in the master data of ControllerMES.
• After the creation of the cultist file, the operator uses CutRite to manually carry out the
optimization.

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• There the results can be modified and after they are accepted CutRite will transfer the data
to the according machine.

5.2 Ignore Cnc oversize

• Given that GeoFrom parts are now produced on a nesting workspace rather than a CNC,
we have added a new tile where the user can disable the GeoFrom oversize globally
because the oversize is no longer needed.

• Ergodesign wanted to maintain the oversize value in the GeoFrom definition in case they
needed to return to the CNC workspace due to problems with the nesting.

• Once nesting is fully implemented and tested, this function will be obsolete.

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6 ControllerMES implementation

6.1 Client installation

• Website for installation DEV: http://mycd-021/wpDevelopment/Application/

• Website for installation PROD: http://mycd-021/wp/Application/

• ControllerMES version DEV : 3.2.5.0

• ControllerMES version PROD : 3.0.35.0

6.2 Production Routes

• The production routes are generated by controllerMES, and the functionality was
already implemented in a previous project phase.

• In this project we have enabled the alternative production routes, but we are selecting
only the first production route and not the alternative production routes. This was
realized due to the requirement of selecting a primary route based on the indicated
priority in the route definition.

• Realized by customizing the WccProductionFindRoutesCust userExit.

• The production routes are managed by Ergodesign.

6.3 Data completion

6.3.1 Route determination (WCC)

Definition Find Route

KeyField Name Description Example

ERP Workflow Describes the PXM workflow name Fixed value as “-”
Describes type of the productionOrder - Sale item (Article)
Application type - Assembly
- Component (Workpiece)
Part list component Only in use for the drawer fronts
Part type from imos iX
type
Describes the cut flag 0 = No cut required, purchased part
Cutting code
1 = Cut required
Describes if the part has surfaces 0 = There is no surface
Coating code
1 = There is surface
Describes the edge flag 0 = No edge available
Edge code
1 = Edges are available
Describes the drilling process 0 = No CNC operations are needed
CNC code
1 = CNC operation is required
The GeoForm describes all non-standard
Geometry Geo01, Geo02, Geo03 and etc.
details that have more than four edges

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Definition Find Route

KeyField Name Description Example

A Narrow part is considered if one dimension - No narrow part

is lower than 120mm. There are multiple - Normal narrow part
Narrow component types of narrow parts - Narrow part with alternative
production path
- Narrow part ,special case
The priority of the production route 10, 20, 30 etc.
Priority
Smaller the number, higher the priority
Production route Describes the production route according to
P – Packing
according to the the ERP
A- Assembly
customer system

• There are two different filter settings behind WccFindRoute.

FindRouteDefault_010

Name of filter: FindRouteDefault

Sequence of filter: 1

Field Operator InputValue

ERP Workflow = ErpWorkflow

Application type = OrderType
Parts lists, part type = PartType
Cutting Code = CutFlag
Coating Code = SurfaceFlag
Edge code = EdgeFlag
CNC Code = CncFlag
Geometry = PartGeometry
Narrow component = NarrrowPartType
Production according to =
customer system ProductionRoute

FindRouteDefault

Name of filter: FindRouteDefault_001

Sequence of filter: 2

Field Operator InputValue

ERP Workflow = ErpWorkflow

Application type = OrderType
Parts lists, part type = PartType
Cutting Code = CutFlag
Coating Code = SurfaceFlag
Edge code = EdgeFlag
CNC Code = CncFlag
Geometry = PartGeometry
Narrow component = NarrrowPartType
Production according to =
customer system #

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Example Data:

Based on the data given in the key fields, ControllerMES creates a PRODUCTION PATH for each
production order. Ergodesign defines this PRODUCTION PATH.

Furthermore, according to the production path, the same information must be generated in routes
and procedures.

6.3.2 Working places

• The complete route assigns the workpiece to different workcenters.

• This assignment is responsible for generating the corresponding data for the machines.

• The workplace for nesting operation already existed – 5040.

Example Data:

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6.3.3 Production routes

• Each production route consists of a series of production steps.

• The production steps describe the sequence of the operations which the workpiece should
go through.

Example Data:

6.3.4 Workstation Assignment

• Translates the machine name from PXM to workplace name in controllerMES.

• There is one filter settings for the DataCompletion.

GetWorkCenterCodeFromCamInformation

Name of filter: GetWorkCenterCodeFromCamInformation

Sequence of filter: 1

Field Operator InputValue

Cam information = CamInformation

Example Data:

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6.3.5 Cutting workstation

• Defines the processing type of the cutting workplaces.

• We have defined workplaces 1010 and 5040 as standard cutting operation

6.3.6 Edge data from Geoform (WCC)

The HOMAG edge banding line can produce rectangular parts with four standard edges. In case of
special contours, a translation table is required (EdgeInformationToEntityShape).

Example Contour Standard with 4 edges, all 4 edges can be produced on the Homag line. No
translation necessary.

Example Contour “Cut out on the right”. The rectangular contour can be produced on the HOMAG
line, the red cut out is not producible. Blue is the Standard contour no, red the special contour no
from imos iX.

➔ The data completion table EdgeInformationToEntityShape is a translation table, in

order to get the correct edge transition for the edgebanding machine

➔ This allows the generation of an adjusted edge shape for parts containing more than 4
edges. Only relevant edges for the edgebanding machine are considered
.

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➔ The following fields coming from imos iX are required:

➢ GeoForm – The geometry of the part is filled by IDENT_INFO4. The default value is
‘Geo01’.
➢ EdgeTransition out of imos iX

➔ The result edge transition of the first entry represents the input of value of the edge
transition of the second entry. The output of the second entry is the input of the third entry
and so on.
➔ According to the information got from imos iX and the relevancy of the edges, the table
outputs a new or the same edgetransition (Result edge transition) that will be used for the
generation of the edgebanding data.

Examples:

1) The following set shows a standard part with only one edge (edge 3 → edge N). The part has
no flip; therefore, it remains with the same edge transition.

2) The following set shows a special part with assigned GeoForm. The edgebanding line can
only edge straight edges, but in this example, edge 3 is not linear so it is not relevant for the
edgebanding machine.

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GetProcessingDataOrientationY

Name of filter: GetEdgeInformationToEntityShape

Sequence of filter: 1

Field Operator InputValue

Component geometry = GeoForm

Initial edge transition = Edge transition
Component mirrored = DataChange
Edge sequence, customer system = EdgeIdInput

GetEdgeInformationToEntityShape_010

Name of filter: GetEdgeInformationToEntityShape_010

Sequence of filter: 2

Field Operator InputValue

Component geometry = GeoForm

Initial edge transition = 999
Component mirrored = DataChange
Edge sequence, customer system = EdgeIdInput

6.4 Edge data generation

• The edge data generation is already implemented in previous project step.

• Ergodesign is controlling the pre-milling before edgebanding of the shaped parts setting
up a special edge geometry for these parts in imos iX.

• This edge geometry is being used in controllerMES to select edgebanding macros

without pre-milling.

• The pre-milling logic for shaped parts is completely managed by Ergodesign.

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6.5 Lot generation

• We have utilized the functionality for the optimization strategies due to the requirement for
two optimization part list files (HPP and NEST) for rectangular parts.

• For this, a custom CutRiteWrapper was created, which only exports the part list files and
doesn't wait for optimization from CutRite.

• The production planner decides in CutRite if the cutting process is executed on the nesting
or on the cutting machine.

• For shaped parts the CutRite's standard manual interface is being used.

6.5.1 Calculate Cutting Dimension

• MES creates the cutting dimension during the standard Edge Data generation process

• Following DataCompletions must be filled with data

o data.ShapePasses
o data.WorkCenterOversizeValues
o data.WorkCenterEdgeProfiles

• The logic for the calculation is the MES “standard logic”

o CuttingLength= FinishLength + AdditionalDimension - Edgethickness

o Cutting width = FinishWidth + AdditionalDimension – Edgethickness

• Example: part with 3 edges(N,W,E), L>W, 1000x500,1.5mm edge, 2mm offset

o CuttingLength = 1000mm + 2mm(W) + 2mm(E) -1.5mm - 1.5mm = 1001mm

o CuttingWidth = 500mm +2mm(N) -1.5mm = 500.5mm

6.5.2 Optimization rectangular parts

• We have configured the following optimization strategies

• The optimization stages are only configured for the workplace 1010 because Ergodesign
does not want the MES to alter the production route or show if the optimization is being
done on the nesting workplace

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• Due to the fact that they have the same structure but different optimization settings, MES is
going to generate two optimization part list files for the 1010, one of which will be utilized for
nesting.

6.5.2.1 Configuration

• LotgenerationCutrite is the name of the configured task, and LotgenerationCutRite is the

name of the optimization configuration.
o Workplace – 1010
o Presetting provided – WritePresettingInTables
o Package provider – Common
o Archive provider – ArchiveProviderCutriteNoAction
o Provider of the result for the optimization – OptimizationResultProviderNoPtx
o Batch number provider – LotNumberProviderDefault
o Cutting parameters and optimization parameters are taken from the strategies for
optimization

• Presetting provided – WritePresettingInTables utilizes the database connection

“ExchangeLotGeneration” configured in the tile “Database connection”

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• Given that MES will not read the optimization results from CutRite, we had to create a
custom external optimization userExit that only sets the right state of the optimization
without waiting for the results.

o Type name of the external optimization - ExternalOptimizerErgo

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6.5.2.2 Scripts for the custom CutRiteWrapper via external DB

• The scripts are located in the folder:

C:\Homag\Scripts

• CutRiteWrapperCust is configured with the following parameters:

• It’s integrated in Windows Scheduler and runs periodically.

6.5.3 Optimization shaped parts

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• We are using the standard manual CutRite interface in MES to create the optimization part
list files for the shaped parts.

6.5.3.1 Configuration

• The name of the configured task is LotgenerationCutriteNesting, and

LotgenerationCutRiteNesting is the name of the optimization configuration.
o Workplace – 5040
o Presetting provided – Cutrite
o Package provider – Common
o Archive provider – Cutrite
o Provider of the result for the optimization – OptimizationResultProviderNoPtx
o Batch number provider – LotNumberProviderDefault
o Cutting parameters - NotInUse
o Optimization parameters – Rectangle

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6.5.4 Delete optimization

• If an optimization is completed and accepted, however the end user wants to delete the
optimization because of a mistake, it can be deleted by using a special tile for that purpose.
The tile “Delete optimizations” displays all created optimizations. With a right mouse click,
the selected optimization can be deleted (this will trigger the task DeleteOptimization) and
the parts are once again available for a new batch formation.

6.6 Server Programms

• There are several jobs responsible for importing the customer orders in ControllerMES.

• All import jobs are already configured in the previous project phase.

• There are no adjustments made to these jobs to accommodate the nesting machine
integration.

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6.6.1 Export bracket

• Exports the data needed for the production.

• Additionally in the export backet, a task for dxf export was configured for the workplace
5040- Nesting

6.7 Feedback configuration

• To be defined once the machine feedback module is activated

6.8 Configuration IgnoreCncOversize

• To ignore the defined CNC dimension multiplier value in the GeoFrom definition, we have
developed a new userExit – WccProductionSetEdgeDefinitionsHelperCust.

• The userExit uses parameter in the program settings which determinates whether the CNC
dimension multiplier is enabled or disabled.

• The parameter has identifier IgnoreCncOversize and it expects two values in the
ValueFloat field.

o 1 – Disables the CNC dimension multiplier

o 0 – Enables CNC dimension multiplier

• The user has the option to change these values from the MES user interface via new
custom tile created for the purpose.

• The tile was constructed as a data view with the following settings:

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1.2 Data reorganization

• The configuration of the data reorganization only applies to the reorganization of the DB
tables.

• The task has a trigger that causes it to be executed each morning at 1:00 AM.

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Reorganization of database tables

Deletion Description Table Condition PackageSize ConnectionName

Order
10 Delete CustomerOrder CustomerOrder DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 120 10000
30 Delete LogItem LogItem DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 30 10000
40 Delete Feedback Feedback DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 120 10000
50 Delete WccStagingRecord WccStagingRecord DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 140 10000
60 Delete Optimization Optimization DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 120 10000
70 Delete Binaries Binary DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 120 10000
&& !ProductionOrders.Any() &&
!PrintOuts.Any() &&
!ProcessingData.Any() &&
!ProductionOrdersResources.Any() &&
!ProductionStepsResources.Any() &&
!WccStagingRecordsResources.Any() &&
!WccStagingRecords.Any()
80 Delete from CustAllErpFeedbackRecord DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 30 10000
CustAllErpFeedbackRecord
90 Delete from CustErpFeedbackRecord DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 30 10000
CustErpFeedbackRecord
100 Clean OptimizationPresettings OptimizationPresetting DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 60 10000
110 Clean OptimizationKPIResults OptimizationKPIResult DbFunctions.DiffDays(ModificationDate, DateTime.Now) > 60 10000
120 Clean LGToOptiOptimizations LGToOptiOptimizations WHERE ModificationDate < DATEADD(day, -30, GETDATE()) 10000 ExchangeLotGeneration
130 Clean LGToOptiMethods LGToOptiMethods WHERE ModificationDate < DATEADD(day, -30, GETDATE()) 10000 ExchangeLotGeneration
140 Clean LGFromOptiKPIResults LGFromOptiKPIResults WHERE ModificationDate < DATEADD(day, -30, GETDATE()) 10000 ExchangeLotGeneration

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7 Lessons Learned

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