PLC Programming and HMI Software

The first step is to define what the machine does and the conditions for moving to the next operation. We consider sensor inputs, motor and drive commands, operator interventions and alarm states together. For a new machine, we define the intended behaviour; for a retrofit, we identify existing operation and the changes you need.

We assess communications between the PLC, HMI and drives alongside the existing hardware. The field signals used by the software and the information displayed on screen are prepared according to this equipment list.

The PLC program executes the machine process sequence. We arrange starting, stopping, manual operation and automatic cycle steps within the same operating strategy. The software defines the permissives required for equipment operation and the effect of fault information on other steps.

• Process transitions based on sensor and equipment states.
• Matching motor and drive commands to the operating sequence.
• Control using the temperature, pressure, level or speed information used by the machine.

HMI screens display machine operating status, production parameters and alarm descriptions. We match operator commands with status information from the PLC program within the same screen structure. Screen sequence, equipment names and setting fields are arranged according to machine use.

For recipe-based machines, we define the values to be selected and the parameters the operator can change. User permissions and action records are defined during project design. When upgrading an existing screen, we also assess the information the operator needs and alarm descriptions that are difficult to understand.

Before a revision, we examine device details, existing program backups, electrical drawings and requested changes. We define tasks individually, such as updating the sequence, adding a parameter to the operator screen or revising alarm descriptions.

We also convert existing relay control systems to PLC and HMI control. The machine process sequence, field connections and operator screens are assessed together. Required software and hardware changes are included in the quotation scope.

For machines without a program backup, we examine the operating sequence and develop the PLC and HMI software anew. This work considers machine process steps, field connections and the commands the operator will use together.

During commissioning, we check sensor input acquisition, motor and drive commands, process transitions and HMI controls on the machine. Alarm notifications, operator settings and defined operating modes are also part of these checks.

PLC/HMI program backups, electrical drawings, an operating manual and operator training are included in our standard handover. For technical service, we connect through the customer's computer or a remote access device when the customer provides internet access. Reviewing software and alarm information helps us assess the need for on-site checks.

Can work be carried out on the PLC program or HMI screen alone?

We assess your requested change alongside the existing PLC/HMI, communications and field connections. We scope program changes and screen upgrades together with any other required modifications.

What information is needed for a software quotation?

Share the machine's function, operating sequence and requested change. Available PLC/HMI and drive details, program backups, electrical drawings and screenshots help with the assessment. Commissioning location and any planned production shutdown are also discussed at quotation.