Project Overview

Our custom middleware solution optimizes data flow between a PLC system and a Manufacturing Execution System (MES) across 20 stations. The middleware stores incoming PLC data in SQL, then forwards it to the MES, effectively eliminating timeout and data loss issues.

Key Features

1. Efficient Data Buffering

The middleware acts as an efficient data buffer, receiving data from the PLC and storing it securely in SQL, helping manage heavy data loads from 20 stations.

2. Asynchronous Data Transfer

By using asynchronous processing, the middleware handles high traffic without delays, improving communication speed and avoiding bottlenecks.

3. Thread-Based Data Handling

Data from multiple stations is managed through threads, allowing the middleware to handle multiple data streams simultaneously, ensuring consistent and orderly data processing.

4. Scheduled Job for MES Transfer

A dedicated job function periodically retrieves stored data and sends it to the MES, reducing load and ensuring efficient, scheduled data transfer.

5. SQL Database Integration

The middleware solution uses SQL Server for data storage, providing a reliable and organized repository for managing real-time manufacturing data.

6. Resolution of Timeout Issues

By decoupling data transfer from direct PLC-to-MES communication, the middleware has resolved timeout issues, ensuring smooth and uninterrupted data flow.

7. Data Loss Prevention

The middleware safely queues and stores all incoming data, mitigating the risk of data loss during peak loads, especially critical for large-scale manufacturing operations.

8. Scalable Architecture

The middleware is built to scale with additional stations or increased data traffic, allowing easy expansion for future operational needs.

9. Real-Time Monitoring and Alerts

The system provides real-time monitoring of data transfer status, with alerts for any interruptions, keeping operators informed and proactive.

10. Enhanced Process Reliability

With its robust design, the middleware ensures that data is consistently and accurately relayed, boosting the reliability of the MES integration and supporting production goals.

Technology Stack

Used: Custom Middleware Solution, PLC Integration, SQL Server, MES System, Thread-Based Processing, Real-Time Monitoring and Alerts.