Automation & PLC
Machine and process control, state machines, PackML, EtherCAT, drive integration, recipes and batch sequences.
TwinCAT 3 · PackML · EtherCATINDUSTRIAL AUTOMATION & SOFTWARE
Making a machine run is not enough.
It should be understandable.
We treat PLC, SCADA, robotics, motion control, functional safety and electrical design as parts of one system. From design to commissioning, we build automation systems that can be operated, maintained and diagnosed on site.
Good automation does more than produce. It shows why a fault occurred, remains understandable during maintenance, and can be extended years later.
Services
From control system to operator interface.
SCADA & Industrial Data
Operator interfaces, alarms, trends, production records, audit trails, recipes, reporting and PLC data integration.
.NET / WPF · ADS · SQL · OPC UARobotics & Motion
Robot cells, servo axes, PLC–robot communication, motion sequences and commissioning.
KUKA · ABB · Servo · CiA 402Electrical & Functional Safety
Electrical schematics, field I/O design, safety PLCs, E-Stops, guard locking, STO/SS1 and safe-stop concepts.
EPLAN · Pilz · SICK · TwinSAFEStandards-Oriented Engineering
Process control, safety and cybersecurity considered as parts of one architecture.
ISA-88-Oriented Batch Architecture
Reusable and traceable control structures that separate recipes, batches, equipment and process control through explicit hierarchies.
ISA-88 approach · Recipe · Batch · Equipment ModelFunctional Safety
Project-specific safety functions and architectures covering E-Stops, guards, guard locking, STO/SS1, safety PLCs and safe-stop behavior derived from risk requirements.
ISO 13849 · IEC 62061 · Pilz · SICK · TwinSAFEIndustrial Cybersecurity
Network segmentation, zones and conduits, controlled remote access, user and role management, logging, backup strategy and access restrictions for machine and process networks.
IEC 62443 approach · Zones & Conduits · Least PrivilegeTraceable SCADA & Data
User actions, recipe revisions, batch history, audit trails and production records designed as a traceable data flow.
Audit Trail · Recipe Versioning · Production HistoryOEM & Machine Automation
Designed not only for one machine, but for the machines that follow.
For machine builders, we treat automation as a reusable product platform that can adapt to variants and remain maintainable in the field. Process and machine-control software is delivered in a documented, sustainable structure.
Modular PLC ArchitectureStandard device structures, explicit state machines and reusable software modules.
Variant & Option ManagementControlled activation of optional stations and equipment across a machine family.
PLC · Robot · SafetyMachine sequences, robot handshakes, motion and safety behavior designed together.
Offline TestingTesting control scenarios, interlocks and handshakes before mechanical assembly is complete.
Process Automation
Traceable control from recipe to production record.
Recipe and batch systems need more than transferring setpoints to the PLC. We design parameter limits, recipe revisions, batch results, production history, alarms and interlocks as one traceable system.
01FieldSensors · Valves · Drives
→02Industrial I/OEtherCAT · Remote I/O
→03PLCTwinCAT · Control
→04SCADAADS / OPC UA · HMI
→05DataSQL · History · Audit
PLC Software Architecture
State transitions in one clear, traceable place.
In our PackML-oriented control structure, state transitions, command priorities and safety-driven stops are centralized. This keeps online diagnostics understandable across machine, subsystem and component levels.
The excerpt below is selected from real PackML transition code in our TwinCAT 3 PLC library.
Engineering Workflow
Turning process knowledge into a working control system.
Concept & FDSFunctions, sequences, P&ID and machine requirements
I/O & HardwareField devices, I/O mapping, motion and EPLAN design
Software ArchitectureModules, state machines, interlocks and handshakes
PLC / Robot / SCADAControl, robot, interface and data-layer development
Offline Test & FATSequence, fault-scenario and functional tests
SAT & CommissioningField validation, commissioning and final checks
Projects
01Examples of our engineering work.
Multi-Stage Process Automation
Central PLC + SCADA control for material preparation, dosing, mixing, extrusion and drying.
Servo Press & Forming Line
Synchronized control of dual servo axes, product transfer and process measurements.
Robotic Assembly & Inspection Line
PLC coordination of robots, vision, fixtures and process stations.
Process & Motion Machine
Multi-axis motion, vacuum, tanks, pumps, valves and temperature control in one cycle.
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Discuss your project →Approach
Software designed for field diagnostics.
Explicit state machines.
The active state and the reason a sequence is waiting should be visible online.
Single command owner.
Clear ownership prevents uncontrolled commands from multiple software layers.
Diagnostics first.
Interlocks, communication, safety and device faults should be distinguishable.
Designed for operators.
SCADA should explain what is happening instead of merely displaying PLC variables.
Safety Integration
Safety status made explicit and traceable in the control software.
Engineering Insights