With the FOAMWARE, Hennecke has established a control platform on the market, which is setting new standards in the production of foams. Thanks to its modern architecture and capable hardware, it not only meets the current market standards, but is also oriented towards future developments. The software combines intuitive operability, comprehensive functionality and seamless integration into existing production environments and IT systems.
Developments for current and future challenges
The development of the FOAMWARE is based on Hennecke's decades of experience and has been redesigned from the ground up. The goal was to overcome the technological limitations of earlier systems such as PURTRONIC and PDE and to create a platform that meets the increasing demands of modern production processes. "During development, we worked closely with our customers and users to integrate their current and future requirements for the control system", explains Eugen Kern, Team Leader Service Sales BU Germany. The software is available in two variants: FOAMWARE Slabstock, which is specially tailored to slabstock machines, and the new FOAMWARE Molded Foam, which has been developed for highly-automated molded form production. Both versions are based on the same software platform and capable hardware.
State-of-the-art hardware offers maximum power and safety
At the heart of the FOAMWARE is state-of-the-art hardware equipment that ensures robust performance whilst also increasing operating safety. The free-standing operator console with a SIMATIC Quad-Core industrial PC of the latest generation and a 32-inch UHD monitor enables ergonomic working and a good overview of a wide range of parameters. Up to three other monitors can also be connected. Furthermore, the basic equipment comprises a printer, an uninterruptible power supply, an air-conditioning unit and a remote access router for online support. Another highlight is the additionally included third-party interface, which allows for the highest degree of connectivity to higher-level ERP systems. It ensures that the system constantly provides all process parameters as an integrative unit.
Comprehensive range of functions and modular developments
Even in its standard scope of delivery, FOAMWARE offers a wide range of functions that make production processes more safe and efficient. This includes visualization of the Flow Chart, Process Chart and Calibration Manager, as well as software tools for the analysis of target and actual values. A highlight is the "Magic Eye" function, which recognizes and immediately presents any metering deviations and irregularities during operation. This allows the user to react quickly to changes to the actual values and saves valuable resources.
Furthermore, the control software also has an impressive flexible plug-in concept, which facilitates the integration of additional modules. This includes, for example, the Hennecke Process Analysis, (HPA), which offers a comprehensive graphical evaluation of production data, and a web service, which enables mobile production monitoring. The modular structure of the FOAMWARE ensures that the software can be adjusted to individual requirements, and also covers future ones.
Optimal results with the FOAMWARE Slabstock
When it comes to slabstock production, the FOAMWARE Slabstock has been perfectly adapted for the specific requirements of this product area. It integrates the RISE PROFILE MEASUREMENT, which visualizes the foam height at various points in the rising process and ensures a constant production quality. Up to 30 data points are measured in the process, which allows deviations in temperature, humidity or activators to be immediately detected.
The FOAMWARE also allows the use of AUTO FLAT systems, with which the level surface of slabstock foam typical of Hennecke is achieved largely automatically. This function ensures constant and reproducible quality, independent of the specific expertise of the user. The reduced material waste further contributes to the protection of resources.
Highly-automated processes with the FOAMWARE Molded Foam
The FOAMWARE Molded Foam has been specially developed for the requirements of modern, highly-automated foam molding plants. Building upon the FOAMWARE platform, a proven success in slabstock foam, it offers an excellent basis for further developments in the area of foam molding applications and covers all the functionalities of its predecessor, PURTRONIC. This includes, for example, functions such as the robot module, thanks to which travel paths can be created, edited and transferred to the robot directly in the software. With interactive and intuitive visualizations, the new solution better supports production monitoring and process optimization and can be quickly and efficiently set up without the need for long training sessions. One of the many new functions for production monitoring is, for example, part tracking, which monitors the quantity of parts produced per mold and deactivates the relevant molds when the nominal number of pieces is reached. This prevents unwanted overproduction and saves both valuable production capacity and most importantly, unnecessary raw material costs. Moreover, the FOAMWARE Molded Foam offers the possibility to exchange reading and writing production data with upstream or downstream systems via a third party interface. This increases the continuity of the digitalization for the customer and saves valuable resources.
No worries all round thanks to retrofit solutions and the new Complete Care contract
Hennecke is expanding its control platform with a comprehensive range of services that ensures the highest level of production stability for the user. The FOAMWARE Slabstock is therefore not only for new systems, but is also an ideal way to modernize existing production solutions. Thanks to comprehensive retrofit solutions, older systems – even those which are 20 years old – can be brought up to the latest technical standard. This includes the integration of modern visualization software and all necessary hardware components.
Markus Häsler, expert in retrofit installations at Hennecke, explains: "With the FOAMWARE Slabstock, we are taking existing systems to a whole new level and making them once again efficient and fit for use." Depending on the conditions on-site, this is achieved with either a standard solution or tailor-made adaptation to ensure optimal performance. As well as increased efficiency, modernization also helps to sustainably ensure IT security. This is particularly relevant as the current process data recording and monitoring system will no longer be supplied with security updates on a Microsoft basis. Furthermore, thanks to the retrofit solution, older systems can also be supplemented with optional additions such as RISE PROFILE MEASUREMENT.
The new FOAMWARE Molded Foam is also an attractive solution for retrofitting existing systems. Moreover, Hennecke is constantly working on further efficient service products and measures for existing production systems.
An entirely new innovation in the service portfolio is the FOAMWARE Complete Care contract. With this, slabstock foam producers can benefit from annual software updates, which integrate all technical improvements, security updates and new functions. The offer is supplemented by regular documentation updates and an included contingent for technical support and regular training. This service concept ensures that the use of FOAMWARE continues to provide growing added value for Hennecke customers and that the software always remains up-to-date.
Consistent transfer of expertise through webinars and training
In the past year, Hennecke has hosted its own webinar series in order to inform customers worldwide of the many possibilities available with FOAMWARE. Furthermore, if interested, individual trainings and interactive consultation appointments can be arranged in order to discuss specific requirements.
Those interested can find more detailed information and personal consultation on the Hennecke GROUP service website at service.hennecke-group.com.
