PLC programming
PLC programming, HMI and SCADA.
We write the control program for a new machine, line or process and modify the one that is already running. PLC, HMI and SCADA on Siemens, Rockwell Allen-Bradley, ABB, Omron and Schneider platforms, with documentation your maintenance team can actually follow.
A program your maintenance team will still understand in five years.
PLC programming is the core of every automated process. It decides how a machine reacts to a fault, how quickly it restarts afterwards, what the operator sees on the panel and what data goes to higher-level systems. A poorly structured program will get the machine running, but every later change is then expensive and risky. That is why we insist on a consistent structure, clear variable names and comments that explain why, not just what.
We design control systems starting from a functional specification. First we write down the requirements for functions, interlocking, protection and fault algorithms, sequences, control loops and communication. Only then do we program in IEC 61131-3 languages, with reusable function blocks and libraries, so the code is clear and testable. Before start-up we test the program in simulation or on a test rig, so on site we fine-tune details rather than the basic logic.
We work with Siemens, Rockwell Automation Allen-Bradley, ABB, Omron and Schneider Electric PLCs, with WinCC, FactoryTalk View, InTouch and Weintek visualisation, and with Danfoss, Siemens, Rockwell and Vonsch variable speed drives. We also link control systems from different manufacturers, for example a main line on Siemens S7-1500 with a packing machine on Allen-Bradley ControlLogix. We supply control systems for machines and assembly lines, as well as for process plants in the energy, chemical and metals industries.
What we deliver for machine and line control.
Bespoke PLC programming
Sequences, interlocks, recipes, closed-loop control and fault diagnostics for machines, lines and process plants.
HMI and operator panels
Clear operator screens with alarms, recipes and diagnostics in the operator's language, in several languages on request.
SCADA and control room
Visualisation of the whole plant on operator stations with trends, alarms and archiving, accessible from the control room and remotely.
Safety PLCs
Emergency stop, safety door interlocks and light curtains implemented on a safety PLC or safety relays to EN ISO 13849.
Industrial networks and communication
PROFINET, EtherNet/IP, DeviceNet, Modbus and OPC UA. Linking PLCs from different manufacturers with each other and with MES or a database.
Program changes and migrations
A new product variant, a sequence change or migration from an older PLC to a new generation without losing functions and with minimal downtime.
What the delivery includes.
We hand over the program tested, commented and with the source code.
- Functional specification and control algorithm diagrams
- PLC and safety function programming
- HMI screens and SCADA visualisation
- Configuration of industrial networks and communication with higher-level systems
- Set-up of variable speed drives and servo drives
- Program testing before start-up and on site (FAT and SAT)
- Commissioning and operator and maintenance training
- Source code, backups and documentation
Platforms we work with
How the cooperation works.
Consultation
We come to you, look at the operation or the brief and tell you what makes sense. Without obligation.
Concept and quote
Technical design, scope, schedule and price. Always with a reserve for what practice reveals.
Implementation
Engineering, manufacturing, installation, programming and commissioning. One team, one responsibility.
Operation
Operator training, documentation and a service contract according to how critical the technology is for your production.
Related services.
Electrical design and control panels
HV and LV electrical design, bespoke control panels, installation, commissioning, inspection and multilingual documentation.
PLC training
PLC, HMI, SCADA, industrial network, servo system and drive courses for maintenance teams and programmers.
Line retrofit
Modernisation of machines and lines: new controls, drives, sensors and safety with minimal downtime.
Frequently asked questions.
Did not find your answer? Write to us and we will reply within 24 hours.
How much does PLC programming cost?
It depends on the number of inputs and outputs, the complexity of the sequences, the number of HMI screens, the safety functions and communication with other systems. A small change to an existing program is a matter of days; new control for an entire line takes weeks to months. We give a fixed price after the functional specification.
Do you program both Siemens and Allen-Bradley?
Yes. We program Siemens and Rockwell Automation Allen-Bradley PLCs, as well as ABB, Omron and Schneider Electric. We choose the platform to match your plant standard, so your maintenance team does not have to learn yet another system.
Can you modify a PLC program without the original supplier?
Yes, as long as we have access to the PLC or a project backup. We first back up and analyse the program, fill in missing documentation and deploy the change so it can be rolled back at any time. If parts of the program are password protected, we sort out access with the machine builder.
Can a Siemens PLC be linked to an Allen-Bradley PLC?
Yes. We did this, for example, on a line where the main section runs on Siemens S7-1500 and the packing machine on Allen-Bradley ControlLogix. Fault messages from both machines are collected in one place via a protocol gateway and sent to the higher-level system.
What is the difference between HMI and SCADA?
An HMI is the operator panel at the machine through which operators control the machine or line. SCADA is the higher-level system in the control room that collects data from several PLCs, displays the whole plant, manages alarms and archives data.
Do you also provide PLC service and training?
Yes. We service PLCs, HMIs and drives with 24/7 standby and remote access. Our programming training focuses mainly on the Rockwell ControlLogix and Studio 5000 platform.
Tell us what the machine should do.
Send us a description of the process, the PLC type if you already have one, and what you want to change. We will get back to you within 24 hours with a proposed approach and a free consultation.