Process Monitoring & Digital Analysis
The Nervous System of Your Production
From the initial data flow concept to cross-site integration into your IT landscape – we develop systems that act as the intelligent control centre of your production and detect deviations before they turn into scrap.
In a connected smart factory, monitoring individual parameters is only the beginning. WSK Elektronik delivers process monitoring solutions that map your entire production line digitally. We aggregate high-frequency sensor data, validate process steps in real time and ensure complete traceability of every component. With over 30 years of expertise in measurement electronics, we bridge the gap between physical production and the digital management level.
Maximum Transparency Through In-Process Data Acquisition
In series production, the greatest risk is being unaware of gradual process changes. Tool wear, fluctuating ambient conditions or drifting sensors often lead to measurable scrap only after hundreds of units – by which time the cause can no longer be clearly identified.
Our goal: to make process changes visible early, before they result in scrap or customer complaints. To achieve this, we combine continuous data acquisition, rule-based evaluation and – where economically viable – statistical trend and wear analyses.
Real-Time Interaction and Intelligent Sensor Aggregation
To increase the efficiency of your equipment, data must not only be captured but evaluated immediately. Our monitoring systems use state-of-the-art interfaces and analysis tools to control your production flow digitally:
- Multimodal sensor integration: Aggregation of haptic, electrical and acoustic signals (e.g. via frequency analysis) to validate the mechanical condition of your tools and products during operation.
- Reactive process control: If limit values are exceeded, the line control (PLC) immediately receives a defined signal, so that defective parts are automatically rejected before they pass through further processing stations.
- Seamless IT connectivity: Standardised protocols such as OPC UA, MQTT and REST APIs connect your MES or ERP system (e.g. SAP) directly to the acquisition level – without manual data transfer.
Determinism Where It Is Needed
Permanent process monitoring must neither slow down the line nor block it through its own failures. The architecture of the WSK Framework takes this into account by clearly distributing tasks:
- Real-time layer (TwinCAT): Time-critical tasks run deterministically with defined cycle times. This ensures that responses to process events reliably occur within the specified takt time.
- Measurement and evaluation layer (LabVIEW): Data acquisition, signal conditioning and online analysis take place in an environment optimised for measurement technology – including preprocessing at the source, so that only relevant events are passed on to the database.
- Visualisation and integration layer (C# / C++): User interfaces, reporting and the connection to higher-level IT systems are implemented in high-level languages – high-performance, maintainable and compatible with your corporate IT.
- Structured SQL archiving: All relevant process values are stored consistently in central databases. On this basis, trend analyses, wear models and predictive maintenance strategies can be set up – by WSK or by your in-house data science team.
Your Path to Connected Process Monitoring
Implementing intelligent monitoring is an investment in your digital sovereignty. Within our proven 6-step process for custom test and monitoring systems, we place particular emphasis on three critical pillars in monitoring projects:
1. Structuring the Data Streams
We translate the flood of sensor information into meaningful key figures and define with you which values need to be evaluated in near real time and which need to be archived.
2. Developing the Communication Layer
We deliver complete integration into your existing infrastructure – from fieldbus to ERP dashboard – with a focus on a seamless data chain without media breaks.
3. Automating Quality Reports
We implement algorithms that generate test reports and process analyses automatically and, in the event of deviations, store high-resolution snapshots of the signal curves for root cause analysis.
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Digital Sovereignty Through Complete Traceability
A process monitoring system from WSK Elektronik is far more than a passive display – it is the active backbone of your quality assurance. By combining precise measurement electronics, deterministic control and end-to-end software integration, we minimise the risk of undetected process errors and complaints. We support you from sensor selection to the statistical evaluation of your production data – consistently focused on monitoring technology that grows with your production. Contact us for an initial technical consultation.
Frequently Asked Questions About Our Process Monitoring Test Benches
Yes. Our modular architecture allows sensors and data acquisition to be integrated into existing equipment as well. Using standardised interfaces such as OPC UA or direct fieldbus connections, we bridge the gap to your existing PLC – usually without major intervention in ongoing production.
We use decentralised preprocessing at the acquisition level: raw signals are filtered, evaluated and reduced to relevant events locally before being transferred to the SQL database. This relieves the network and ensures that responses to limit violations occur within the specified cycle time.
Yes. Process data can be transmitted to central cloud instances or group-wide databases via MQTT, OPC UA Pub/Sub or REST APIs. This enables cross-site benchmarking of your production lines – including standardised KPIs and comparable trend data.
Limit values, sensor profiles and monitoring logic can be configured via the graphical interface of the WSK Framework. Where provided, variants are detected automatically via RFID, barcode or a signal from the MES; the system switches to the appropriate monitoring profile without manual intervention.