PLC software and motion control
Automation logic, motion control and process regulation on all the main PLC platforms, from functional analysis to on-site commissioning.
We design and program the control logic of machines, production lines and process plants, following the whole life cycle of the project: from the functional analysis agreed with the customer through to FAT/SAT commissioning on the plant floor. We write structured code to the IEC 61131-3 standard, for cleanliness, maintainability and scalability.
The technological core
We work on all the main PLC platforms, both PC-based and traditional. Our deepest experience is on PC-based architectures, where PLC, multi-axis motion control, safety and communication run on a single controller. The software is tested on a simulator before it is downloaded to the hardware, so debugging does not move to the field.
The choice of platform follows the project and the standards already in use on site: a modular approach built around portability ensures the same software quality on any technology and full integration into the installed base.
What the service includes
- Functional analysis and automation specification
- Structured PLC software development (IEC 61131-3: ST, LD, FBD, CFC)
- Motion control, from axis sizing to on-site tuning
- Process regulation: PID loops for pressure, flow, temperature, humidity and level
- HMI/SCADA integration and interfacing with existing MES/ERP systems
- Factory Acceptance Test in our workshop and Site Acceptance Test on site, complete with final technical documentation
Machines with electric drives
In discrete-cycle machines, throughput and quality depend on how the axes move. We size motors, drives and gearboxes from the real load profile (torques, inertias, gear ratios, thermal verification) and define motion profiles optimised for cycle time or for mechanical stress.
- Synchronised axes: electronic cams and gearing, real or virtual master, conveyor tracking and on-the-fly pick-up
- Torque and force control where the process calls for it
- Tuning of position, velocity and current loops
- Motion diagnostics: following error, saturation, residual vibration
Skids and process plants
Process automation deals with continuous quantities and with transients that must be governed: a different way of designing from discrete-cycle machines, calling for real expertise in control loops and field instrumentation. It is one of our established areas: oleodynamic and hydraulic skids, fluid conditioning stations, cooling and lubrication circuits, pressurisation units, dosing and treatment plants.
- Management of pumps, proportional and on/off valves, heat exchangers and cooling units
- Dosing and blending, with ratio and recipe control
- Start-up, shutdown, recirculation and flushing sequences
- Alarm and protection logic on levels, filters, temperatures, pressures and minimum flows
HVAC and climate control
We automate climate control systems both for the comfort of the spaces and for production processes: air handling units, chillers, heat pumps and hydronic circuits, with seasonal sequences, free-cooling and energy-saving logic.
Whether it is the comfort of working spaces or environmental conditions that are part of the process specification (cleanrooms, temperature-sensitive processes, laboratories), HVAC is designed with the same rigour as machine control: tuned loops, meaningful alarms, continuously recorded data and, where needed, pressure cascades and traceability for validation.
Electrical design and control panels
Control architecture, electrical schematics, control and power panels and bills of materials for machines and plants, per IEC/EN 60204-1 and the Machinery Regulation.
Learn more → 03Functional safety
Risk analysis and safety function design according to EN ISO 13849, from Performance Level calculation to final validation.
Learn more → 04HMI, data and supervision
Operator interfaces, collection and historization of process data, supervision and line KPI dashboards: from the machine to decisions.
Learn more → 05Test benches and end-of-line testing
Automatic test benches and end-of-line test stations: data acquisition, test cycle execution, acceptance criteria and automatic reporting.
Learn more → 06Support, retrofit and consulting
Maintenance, retrofit and remote support on existing plants, including third-party ones, and technical support at the decisive stages: machine fleet assessment, specifications, independent verification during acceptance testing.
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