Fully automatic production control and monitoring

For decades, Compass Software of Dortmund/DE has been supplying customers with solutions for the control of CNC machining centers for milling solid structural wood elements, especially for the construction of staircases and, for several years, for the timber construction sector as well. Additionally, Compass’ software now controls fully automated production units with a robotic loading of drywall and OSB panels. Also, Compass solutions organize the entire production of Dutch staircase manufacturers with an output of up to 100 stairs per day – from the preparatory work to delivery.

Recently, Hasslacher Group decided to use this extensive know-how for the organization and control of a new cross-laminated timber production at its production site in Stall im Mölltal. Previously, Compass Software had already started up the existing, highly complex machining center for wall and ceiling elements. Another CNC machine – a Biesse Rover B supplied by Handl of Wels for the machining of small and special elements as well as for the nesting of small elements – has been connected to the machining center. “In the production of cross-laminated timber with a working surface of 6.4 x 2.2 meters, the term ‘small’ is relative, though”, says Peter Handl, manager of Handl, with a smile.

Everything connected in one system

One of the main advantages of the Compass software is that it is able to connect machines of various manufacturers and different generations with each other in one system and even to let them work together in production lines. In this specific case, one software controls all existing as well as all new processing and machining centers which are used at the production site in Stall.

In Hasslacher Group’s new production, large master panels, which contain several components in a nesting, are first divided and separated. During the separation, some work on the parts is done already (for example, on the bottom). The system turns these components around and then checks them into the production line. From this point on, the Compass software takes control of the production and automatically controls both the CNC machines and the conveyor system. This means that the software assigns the components to other CNC machines in order to achieve a balanced utilization. The cranes which move the components are also automatically controlled.

“The best fully automatic system is of no use, when malfunctions and faults occur or when components are to be fed into it from the outside. For these requirements, the system offers extensive options which allow a manual intervention in production and in the software”, explains Handl.

Real-time graphical representation

Last but not least, continuous monitoring is needed for this type of production. This is can be done in different ways. Of course, the entire production including the flow of the parts is graphically displayed in real time, which allows the operator to see the status of the entire production at a glance. This can be done during production planning, but also at the various control points in the actual production process. All stations of the system have access to the same data in an object database on a central server. All changes in the system can be displayed in real time on all computers in the network.

In addition to the graphical representation, the current status of each element and each station is available at any time in tabular form in special views. This is not only possible on stationary PCs, but also on mobile devices, such as smartphones. “Even the forklift driver, who assembles the packages for delivery and loads them onto the trucks, can be provided with the information which is important for him”, explains Lukas Hollinderbäumer, project manager at Compass, and says: “Together with Compass Software, Hasslacher Group is heading towards a very flexible future with room for further development in terms of cross-laminated timber production.”