Reliable and scalable software

Our manufacturing client required an advanced, cloud-based software ecosystem to streamline the management, planning, control and operation of CNC machines. The goal was to create a holistic digital environment that would future-proof their manufacturing processes and seamlessly integrate complex workflows.

Our client, active in the gaming industry, required a realistic wheel-based driving simulator for high-performance racing simulation systems. The project required expertise in software, hardware and embedded systems to provide a responsive and realistic driving experience.

Our client, a major player in the electric vehicle industry, required comprehensive engineering services for the development of an electrical inverter control unit. The project aimed to integrate mechanical, hardware and software aspects while complying with industry standards such as ASPICE, AUTOSAR and ISO 26262 to ensure safety and reliability.

Our client, a leader in electric vehicle technology, required verification and validation of inverter designs to ensure reliability and performance in demanding automotive applications, including extensive testing of inverter prototypes during development and in-depth analysis of any early failures during product launch. The aim was to identify potential problems at an early stage, validate design accuracy and provide reliable performance data to support a successful product launch.

To optimise product testing capabilities, our customer required a standardised test station capable of performing in-circuit and functional tests for a wide range of products. This station needed to accommodate various test fixtures and provide a streamlined, repeatable test process. By implementing this standardised test setup, our customer wanted to improve the efficiency, accuracy and scalability of product testing.

Our medical imaging client required a streamlined solution for deploying and updating radiology software across multiple hospital sites. The goal was to develop scripts and tools that would enable automated remote deployment to ensure radiology systems were always up to date and operating efficiently without disruption to critical medical services. This project required a strong focus on automation, system monitoring and remote configuration capabilities to support the demanding requirements of a medical environment.

Our client required a web-based monitoring interface for their industrial software solution. This interface needed to utilise data analytics, provide real-time insights and provide intuitive control for managing multiple assets and devices. The project required a user-friendly design and a robust backend to handle large amounts of data and ensure seamless user interaction, making this interface a critical tool for operational efficiency.

Sustainable PLC and HMI development with the latest technology in the spirit of environmental awareness.

Leading in biotechnology with the latest Siemens HMI technology. From conception to implementation, covering the entire development process from the feasibility study and development documentation to the complete development and its realisation.

This project involved the virtualisation of the automation and IT infrastructure of Solupharm Pharmazeutische Erzeugnisse GmbH. The main task was to modernise an existing production line by converting physical IT resources into virtual machines to ensure greater flexibility, reliability and lower costs.

In the HEITEC-TEVA project, the main task was to connect TEVA's production systems to a digital platform in order to increase efficiency. To do this, the production plant at the Blaubeuren-Weiler site was connected to a virtual server using an edge gateway device to collect and analyse real-time production data without affecting the existing system. The main tasks included enabling data processing and visualisation through a web-based HMI application and optimising production through real-time monitoring and predictive maintenance, which increased machine availability and overall equipment effectiveness (OEE).

The project involved the implementation of a digital production data acquisition (PDA) system for the production lines of confectionery manufacturer HOSTA in order to record and visualise production data. The aim was to use the insights gained to increase the efficiency and quality of production and realise energy savings.

HEITEC developed a fully automatic laser setting system for fountain pen nibs for the German market leader for writing instruments. In order to meet the high quality standards, it is necessary for each nib tip of a writing tip to be straightened. The two nib legs are to be straightened to a predefined gap dimension.

Gasitech Industrie-Gas-Handelsgesellschaft is one of the most efficient companies in the field of recurring testing, industrial processing and filling of gas cylinders in Europe. A new processing plant for gas cylinders was to increase capacity, improve quality and make working conditions easier for employees.

The search for the right edge computing power or a suitable gateway can be a challenge given the sheer complexity of the market. Developers and manufacturers of industrial applications are faced with the decision of choosing the right technology today in order to achieve the desired performance and connectivity tomorrow. Ideally without technical restrictions or obvious financial risks, for example if conversions and upgrades become necessary at a later date. HEITEC utilises the possibilities of plug-on technology with HeiSys for a multi-scalable and future-oriented system solution that offers almost countless possibilities.

Planning, engineering and production of navigation and communication systems, as well as low-voltage switchgear. Planning of the entire cable system.

Increasing the safety and quality of the media supply for aseptic filling of syringes, cartridges and vials.

Planning, engineering and production of navigation and communication systems, as well as low-voltage switchgear.

HEITEC and SCHOTT in a dialogue of technologies - in the pharmaceutical industry, it is the microscopically small details that determine the quality and safety of vital medicines. HEITEC is setting new standards in the production of medical vials with a handling system customised especially for the SCHOTT Business Unit "Pharmaceutical Systems". Thanks to the expertise of HEITEC Systemtechnik from Austria and the close cooperation with the customer, the future of pharmaceutical packaging is being reshaped with innovation, precision and intelligent automation.

Carl Schlenk AG is a leading international manufacturer of metal powders, effect pigments and metal foils. With a new building, Schlenk also wanted to reorganise its logistics processes in production with the aim of gaining an overview of material consumption and material receipts in real time.

HEITEC develops test stands for market-leading medical technology and electronics companies for the multiaxial, dynamic application of mechanical loads to test objects.

HEITEC supports a leading eye laser company with innovative electronics development, testing technology and the design and integration of medical PCs for the customer's end application. The laser in the system is used for refractive surgery and is used to treat short- and long-sightedness, astigmatism and presbyopia.

On behalf of Nord-Micro, HEITEC AG developed and built a fully automated test and adjustment system for extended exhaust valves on the Boeing B787 model.

HEITEC developed a standard test system for Diehl Aerospace, which is used both in production and internationally in the repair stations. In conjunction with various test adapters, it is used for the functional testing of different aircraft electronics components, such as cabin lighting and emergency power supplies. In addition to functional tests, dielectric strength tests (with AC and/or DC voltage) and measurements of insulation resistance are also possible.

LEDs have numerous advantages. They ensure greater colour fidelity, show almost no changes in brightness, reduce weight by around 30 percent, consume around 50 percent less power and last much longer. This leads to improved lighting quality for passengers when dimming and ensures a pleasant on-board atmosphere and therefore greater comfort for passengers. HEITEC developed an adapter device that controls the LEDs. The requirements were developed together with the customer.

Aircraft test system with a modular real-time system for testing and integrating safety-critical products. Fields of application are the testing of software modules for aircraft equipment and virtual system integration when it comes to imitating extreme situations that cannot be realised in reality.

It was becoming increasingly difficult to procure spare parts for an order picking warehouse from the 1990s, including the control technology based on Simatic S5, as the control components had been discontinued for some time. The risk of long, incalculable downtimes in the event of a component failure grew steadily. Continuous safe operation was no longer guaranteed. HEITEC was commissioned to analyse the current situation and the risk of failure and to carry out the retrofit.

Hengstenberg GmbH & Co. KG develops and produces sour, wine vinegar and delicatessen products and stores its products in a high-bay warehouse at its site in Bad Friedrichshall. Three storage and retrieval machines supply two storage areas, which can accommodate single or double pallets. The companies Artschwager & Kohl Software GmbH and HEITEC AG were commissioned to modernise the three storage and retrieval machines, the conveyor technology and the safety equipment in the final packaging, storage and canning areas as well as the warehouse management system.

The AWT system at Fulda Hospital controls around 360 transport containers underground and away from the flow of patients, with the help of which the supply and disposal of each hospital ward is ensured. The modernisation was intended to ensure the availability of the AWT system in the future and find a solution for the problematic procurement of spare parts as well as enable future expansions of the system. In addition, the basic functionality of the system had to remain as unchanged as possible despite the implementation of modifications and troubleshooting in order to minimise the training requirements for the hospital staff.

The high-bay warehouse, built in 1980, has a capacity of 3,800 storage locations, which are divided into eight racks. Previously, the processes were controlled with SIMATIC S5 135U and operated via COROS. Many of the HW components were discontinued at the end of the 1990s and a continuous supply of spare parts was no longer guaranteed. In order to ensure the availability of the high-bay warehouse in the future, it was necessary to modernise the control and drive technology as well as the safety technology.

HEITEC AG was commissioned by Loparex Germany to modernise one of its existing film winders with the designation "Winder E27". A retrofit was necessary to ensure the operation of the system with increased availability, current safety standards and a guaranteed supply of spare parts for the future. This was based on the consideration that a retrofit can be more sensible for existing systems than replacing them with new ones, as it results in less downtime and lower costs. By replacing obsolete components and adding new, up-to-date technological developments, existing systems are brought back up to date. This reduces the risk of production downtime and employees can continue to work with the familiar technology, making extensive training unnecessary. A retrofit also has a positive effect on product quality.

Powerful infrastructures are needed to realise network expansion even in remote areas of far-flung countries. HEITEC has developed a high-end system platform for the market leader in lasers for fibre optic cables and telecommunications solutions. The platform is a network node (hub) that receives and distributes the various signals of a DWDM (Dense Wavelength Division Multiplex) network. Up to 96 signals with different wavelengths are transmitted via fibre optic pairs. With appropriate optical amplifiers, transmission distances of up to 1000 km can be achieved at transmission rates of up to 10 Gbit/s per channel. The requirements for transmission performance per slot, reliability, high availability and simple maintenance are correspondingly high.

HEITEC has realised a cost-efficient housing for a provider of communication solutions, which uses standard components as far as possible, but has been modified as necessary and as required.

The lightning measurement device detects and analyses all the important parameters of lightning impulse currents in order to provide a better basis for making maintenance decisions. Offshore wind turbines in particular require a robust, reliable system due to the demanding climatic conditions on the high seas and the vibrations that occur at the installation site.

Vestas Wind Systems A/S (Copenhagen Stock Exchange: VWS.CO), based in Aarhus, Denmark, is the largest European manufacturer of wind turbines and, together with Goldwind and GE Wind, one of the largest in the world. The headquarters of Vestas Deutschland GmbH (Vestas Central Europe) is located in Husum. The company has been active here since 1986 and employs around 2000 people. Heitec carries out the finalisation work for wind turbines with medium-voltage switchgear from certain manufacturers and the integration into a wind farm consisting of several wind turbines.

In co-operation with Siemens Energy, HEITEC builds automated inspection systems for gas turbine blades. The modular inspection system is used for the inspection and three-dimensional measurement of gas turbine blades. Depending on the inspection task, different thermographic and optical methods as well as a 3D measuring method are used.

HEITEC has developed and manufactured a complete system control solution for HVDC (high voltage direct current transmission) systems for one of its customers in the energy technology sector, which centrally controls power modules via fibre optic cables.

HanseWerk AG is an energy service provider with a focus on grid operation and decentralised energy generation based in Quickborn. The company operates around 51,000 kilometres of electricity and 27,000 kilometres of gas lines in many municipalities in northern Germany itself or via its subsidiaries. It supplies around 1.3 million customers in the federal states of Schleswig-Holstein, Hamburg, Mecklenburg-Western Pomerania, Brandenburg and Lower Saxony with electricity, natural gas, water and heat.

Vossloh Locomotives is one of Europe's leading manufacturers of diesel locomotives for shunting and mainline operations. The standard portfolio includes three diesel-hydraulic (G 6, G 12 / G 18) and two diesel-electric models (DE locomotive variants, such as DE 12 / DE 18); the current range of locomotives is based on the modular principle. In addition, dual-mode locomotives (electric diesel locomotives) are being developed and a wide range of services offered.

The BorWin3 project - an offshore wind farm - in the North Sea with a transmission capacity of up to 900 megawatts will be able to supply almost one million German households with wind energy from 2019. A consortium between Siemens AG and Petrofac International from the United Arab Emirates is carrying out the complete construction of a so-called HVDC (high voltage direct current transmission technology) platform. The energy from offshore wind turbines will then be transmitted to the mainland with virtually no losses. There, the energy is fed into the supply grid in an alternating current direction.

In close cooperation with its customer, a supplier of electronics for railway technology, HEITEC developed a universally applicable housing and system solution that can be used for various applications in trains. Thanks to its modular design, it can be flexibly adapted to the respective application and enables simple built-to-order configuration.

HEITEC has developed a universally applicable functional test system based on the PXI system using a test stand and Lab-VIEW. This test system covers a wide range of functional test requirements for printed circuit boards, which can be contacted either by means of plug-in or needle bed adaptation.

HEITEC has applied its extensive expertise to design and manufacture the electronics for a laboratory device for a leading specialist supplier of spectrophotometers. The customer manufactures spectrophotometric instruments for analysing samples in very small volumes, which are used in particular in biological, chemical and pharmaceutical laboratories.

HEITEC supports a leading supplier of medical technology products in the integration of industrial computers for the customer's end application. The linear accelerator is used for radiotherapy in cancer treatment. The medical computer forms the control console for the entire system. The control console controls and monitors all functions of the linear accelerator. The radiologist's or oncologist's radiotherapy plans are technically implemented in the system and all safety functions are guaranteed. All information and data from the linear accelerator is collated in the medical PC and can therefore be monitored in real time.

Material dosing systems are in great demand in the industry due to the increasing miniaturisation of all electronics and the associated tasks and applications for the precise dosing of adhesives, sealants, lubricants and other materials. HEITEC supplies a manufacturer of such dosing systems with the central control unit, which is specially customised to the customer's own valves.

Devices for medical technology applications are in a strictly regulated market and are therefore subject to stringent requirements. HEITEC manufactures the complete neurostimulator for one of its customers - an innovative company specialising in the research and development of electromagnetic stimulators.

HEITEC has realised a cost-effective housing for one of the world's leading technology providers in the field of high-performance industrial image processing, which consists largely of standard components and has been fully adapted to the customer's requirements with just a few modifications.

HEITEC has developed an automated ASIC function test system. ASIC chips (Application Specific Integrated Circuit) are application-specific circuits whose functions consist of digital and analogue function blocks.

On behalf of a customer, HEITEC has designed a compact, multifunctional system that simultaneously functions as a control unit, gateway and output unit. The device is suitable for connecting various analogue devices, linking sensors and controllers as well as connectivity to the cloud. Many communication interfaces and protocols as well as fieldbuses such as PROFIBUS or PROFINET are supported. This means that the required data is accessible at all times. The system enables connection to various cloud solutions such as IBM Cloud, Microsoft Azure and others, as well as connection to MES systems on site.

In order to ensure a very high level of reliability, no rotating components are normally permitted in railway technology, so that possible causes of damage are minimised. A HEITEC customer had planned the use of a higher-performance CPU for one of its existing systems in the railway sector In order to ensure a very high level of reliability, no rotating components are normally permitted in railway technology, so that possible causes of damage are minimised. A HEITEC customer had planned the use of a higher-performance CPU for one of its existing systems in the railway sector. This significantly more powerful CPU had to be cooled due to the high heat development. This required the use of fans that were not provided for in the previous system.

Extremely high precision and very good image results are required for the exposure of printed circuit boards. This is why Laser Direct Imaging (LDI) systems are used here, whose laser beam is focussed on a circuit board coated with lacquer, exposing it. Very high demands are placed on such systems with regard to cleanroom specifications. They must also function with the utmost precision and be extremely fail-safe. Temperature management with regard to high currents, ventilation and electromagnetic compatibility (EMC) are therefore important aspects.

HEITEC supports a leading company in industrial X-ray technology with inspection technology, as well as the design and integration of industrial computers for the customer's end application. The fully automated X-ray system X-rays aluminium rims immediately after production to detect inclusions and other defects. Damaged rims can thus be identified and sorted out. The X-ray system itself uses an industrial robot and a degradation-free detector in conjunction with state-of-the-art image analysis software. The robot grips the rim and holds it at defined angles in front of the sensor. This enables almost pseudo-error-free evaluation of the results, including stable image quality.

HEITEC develops and builds innovative, fully automated production lines with state-of-the-art automatic testing systems for plastic headlight lenses for the ZKW Group.

On behalf of SMP-Samvardhana Motherson Peguform in Bötzingen, an exterior/interior supplier to several premium automotive brands, HEITEC designed and built an automated testing system for door side panelling.

The zero-defect strategy is an absolutely essential target definition in the automotive industry. The issue of quality assurance is therefore becoming increasingly important. Innovative measuring and testing technologies for industrial use play a key role here. SMP-Samvardhana Motherson Peguform in Neustadt an der Donau, an exterior/interior supplier to several premium car brands, commissioned HEITEC to develop a new fully automated test system for testing front bumpers.

Production start from zero to one hundred - In August 2020, four of the fully automatic HeiDetect Wheel Robot wheel testing systems from HEITEC PTS were to be put into operation at the BORBET Group's plant in Thuringia. The four wheel testing systems were to be 100% ready for production after the production break for the start of the foundry in Thuringia. The usual start-up time was not planned - from zero to one hundred was the motto! In addition, the entire production at BORBET in Thuringia was to be converted to 100% traceability of the wheel data across the entire value chain using DMC labelling.

Panasonic produces complex CSC modules in various sizes for the e-mobility division of car manufacturer BMW. These control the correct charging and discharging in the vehicles. As critical components, their manufacture therefore requires the highest technical precision and multiple checks of each production step. In close cooperation with Panasonic and BMW, HEITEC Slovensko developed and installed a complex nine-part production and testing line, the reliability and efficiency of which has already led to further orders.

A leading international company in the fields of variable camshaft phasing units and transmission valves commissioned HEITEC to virtually commission an existing plant in order to identify potentials with the help of the digital twin on the basis of a cycle time optimisation measure and thus initiate targeted retrofit measures. In addition, technologies from the field of special machinery and plant engineering such as bulk material separation with 3D image recognition, belt and film conveying, new drive and clamping processes as well as software-in-the-loop with Siemens PLCSIM Advanced and Epson robot systems posed new challenges.

Holopack Verpackungstechnik specialises in the contract filling of cosmetic and pharmaceutical products. Efficient filling technology plays a very important economic role here. Holopack was looking for a solution to increase production capacities in the manufacture of sterile and non-sterile, low to high viscosity pharmaceuticals. An intelligent automation solution with a batch management system was required to control the system - including a high-performance homogeniser.

Renner Etikettiertechnik is an internationally oriented supplier of professional labelling systems for the food and beverage industry. The automation specialist developed new technology components for the newly developed labelling system and integrated them into the overall system control. This was then tested on the digital model in order to recognise and rectify errors at an early stage.

Raytheon Anschütz GmbH is a subsidiary of the Raytheon Company (USA). The company was founded in 1905 as Anschütz & Co. after Hermann Anschütz-Kaempfe invented the gyrocompass. Today, Raytheon Anschütz develops, produces and tests gyrocompasses, daughter displays, autopilots, manual rudder control systems, radar equipment and electronic nautical charts, as well as complete integrated bridge systems at its site in Kiel. Heitec was awarded the contract for the expansion of the plant's power supply to the medium-voltage feed.

Duscholux is one of the world's leading manufacturers of sanitary facilities. As a long-standing partner for the automation of production systems, HEITEC modernised the control technology. The aim was to further increase plant availability and production reliability.

VACUUMSCHMELZE (VAC) in Haunau develops, produces and markets speciality materials and products refined from them. The modernisation of the control and regulation technology was intended to increase the availability and operational reliability of five bell annealing furnaces. The systems were previously monitored and controlled via a centralised control system and a single operating and monitoring system. An important customer requirement was to be able to operate each furnace independently and to install an additional operating and monitoring system in the control room to manage and distribute recipes. In addition, the logging of process values was to be modernised and a convenient user administration system set up.

Mobile, internet-supported data acquisition and corresponding communication tools have become indispensable in the production of many industrial companies. HEITEC therefore developed a system solution for one of its customers that enabled complex measurement data acquisition as part of the internal production of liquid filter systems. High standards applied to both the electronics and the mechanics. The systems had to function reliably even in the event of high temperature fluctuations and strong shocks and vibrations. Furthermore, insensitivity to splash water, dust and lubricants was required. Taking into account the technical specifications, the systems also had to be as easy to maintain as possible.

Kroenert GmbH & Co. KG is an internationally active manufacturer of coating, printing and laminating systems. The Hamburg-based company with over 110 years of tradition supplies turnkey system solutions in coating technology for web materials such as paper, film and foil. The product range includes complete systems as well as an extensive programme of winders and unwinders, more than 60 modular application systems as well as dryers, humidifiers and laminating units. Kroenert commissioned Heitec to generate a digital twin for the winders and unwinders to improve development, production and commissioning. At the same time, the simulation had to be able to be parameterised in real time in order to do justice to the high variability of the machinery.

The Netzsch Group is a globally active family-owned mechanical engineering and equipment manufacturing company. The company built a new production facility in Selb for the manufacture and assembly of devices for thermal analysis, thereby expanding its capacity by 60 per cent. As the devices are increasingly geared towards customised requirements, Netzsch has streamlined its processes and geared them more efficiently towards individual production up to batch size 1, quality and efficiency. To achieve this, all processes had to be networked with each other.