Web-based process control system for a 4-level body storage facility at AUDI Ingolstadt — with pearl-chain sorting, color-block formation and OPC-UA integration.
The plant comprises 4 levels for storing and sorting car bodies to be fed to the paint shop. A rule-based process control system ensures paint-line continuity, pearl-chain sequencing, and color-block formation throughout the process.
Storage and sorting of car bodies across 4 plant levels.
Continuous sorting by pearl-chain sequence with color-block formation.
Highly flexible material flow rule administration via a generic rule engine.
Plant controller integration and peripheral systems via OPC UA and Siemens Cloud Connectors.
Skillworks FSS PCS at the AUDI control room in Ingolstadt
The web-based PCS runs entirely in the browser of the AUDI control room in Ingolstadt. All levels of the sorting buffer and related systems are visible on the video wall — with states and material flow.
Rule-based material flow control — flexibly configurable
The heart of the PCS is a highly flexible rule engine for material flow control. Rules can be administered by the customer without programming knowledge. The generic approach allows great flexibility as production requirements evolve.
Web-based plant layout ZFS PVC with body IDs
Each plant level — ZFS PVC (level 1), FSS levels and feed conveyor — is available as an interactive web layout. Body IDs, staging lines and transfer car positions are displayed clearly.
Car body master data administration — directly in the browser
To use car body attributes in rule definitions, a flexible administration interface was provided. The master data management is integrated with the customer's internal system — changes are synchronized automatically.
The process control system is built on a modern, containerized Linux stack — optimized for robust 24/7 availability in industrial environments.
Linux · Docker · NGINX · Tomcat · keepalived
Java · Spring · PostgreSQL · ActiveMQ · REST
AngularJS · web-based control room application
Grafana · Kibana · Prometheus
OPC UA (FSS levels) · Siemens Cloud Connector · REST
We have deep expertise in developing web-based process control systems for industrial automation. Get in touch.
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