MiConnect Technology Powers Automation for this Medical Device Manufacturer

To meet these requirements, the customer selected Caron Engineering’s MiConnect Technology as the core cell controller. MiConnect is a versatile and intuitive application builder for manufacturing, and an ideal solution for this complex integration. To start, the customer mapped out a flow chart of the devices and data stream, and leveraging MiConnect with its inventory of pre-built device drivers and flowchart-based design interface, Caron Engineering created a customized application to fit their specific requirements. MiConnect provided a centralized platform to manage data flow, synchronize communication between all manufacturing devices, and seamlessly integrate with MES and ERP systems.

One of the standout features of this implementation was the ability to queue and manage jobs directly from the MES. Operators could input job orders into the MES, which MiConnect translated to the Robot PLC, directing the cell to produce specific parts in precise quantities. The MiConnect interface also allowed operators to reorder job queues in real-time, enabling flexibility in production prioritization. A custom dashboard displayed real-time job progress, including completed jobs, enhancing visibility and efficiency. This automation eliminated manual paperwork and intervention, allowing the cell to start and run unattended as new jobs were continuously queued.

MiConnect’s integration for advanced maintenance monitoring was another key component. By interfacing with the MES, the system checked and enforced preventive maintenance (PM) schedules for all cell components, including CNC machines, CMMs, and robots. If a device required maintenance, MiConnect locked out that portion of the cell while allowing other areas to continue running, ensuring maximum uptime and efficiency.

Additionally, automatic chuck changes were introduced—something never before done in the U.S. This process, primarily facilitated by MiConnect, ensured the correct hardware was in place before initiating a job, reducing errors and optimizing machine utilization.

The MiConnect solution delivers both the simplicity required for basic processes and the sophistication needed for comprehensive control and communication between CNCs, measurement devices, and robotics, enabling seamless lights-out manufacturing. MiConnect ensures that each manufacturing operation is executed correctly before advancing to the next step. With customized user screens, customers can display all critical process information directly on the HMI, streamlining operations and enhancing efficiency.

MiConnect provides a unified platform that supports multiple communication protocols enabling rapid customization without coding. The flexibility of the software allows for on-the-fly changes, which is essential when integrating high-level, complex automation systems. Additionally, MiConnect standardizes communication to a single Ethernet connection for all devices, reducing network complexity.

Unlike traditional SCADA or machine-level software solutions, MiConnect functions as a mid-tier solution, bridging low-level automation protocols (FOCAS, MODBUS TCP, REST) with high-level MES/job modeling. This versatility makes it a cost-effective alternative to custom integrations, significantly reducing both development time and ongoing maintenance complexity.

RFID Tool Management and Automated Tool Wear Compensation

The setup also called for advanced automated tool management and real-time compensation solutions, which Caron Engineering’s technology portfolio provided. Using ToolConnect, Caron Engineering’s RFID-based tool data management system, the company automated tool loading and tracking, improving both accuracy and efficiency.

In addition, AutoComp software was implemented to automatically process measurement data from the CMMs, calculate necessary tooling adjustments, and feed this information back to the control system for precise compensation. This eliminated manual intervention, removing error from the process and closing the loop on the automation cell.

The Results

• Faster Implementation: Caron Engineering provided a tested MES integration model within days—a process that traditionally takes weeks.  

• Dynamic Adjustments: MiConnect allowed real-time process changes, essential for implementing new automation features like automatic chuck changes.  

• Cost Savings: Without MiConnect, the manufacturer would have needed multiple custom software solutions, significantly increasing costs and requiring extensive development time.  

• Simplified Network: MiConnect consolidated communication to simple Ethernet connections, reducing network complexity and integration challenges.  

• Lights-Out Manufacturing: The automation integration of the all the systems with MiConnect allowed the cell to run continuously, and completely unattended.  

This customer success with MiConnect not only optimized this manufacturing cell but set a new automation standard across its global operations. With the ability to scale and adapt to evolving production needs, MiConnect continues to drive efficiency, flexibility, and innovation in the company’s automated manufacturing strategy.