Faults that interrupt the cycle
Diagnostics link PLC messages, drive status, handling equipment position and the conditions for each step. The modification addresses the cause and is followed by a sequence test.
Offered solution
PLC programming and control modifications
We program new functions, modify operating sequences and diagnose equipment in the context of its mechanics, drives and operators.
Operating context
The whole application matters.
A software change starts with a description of the required equipment behaviour. We review modes, dependencies, signals and fault responses, then define the PLC changes, coordination with drives and visualization, and test scenarios. For retrofits, available backups are compared with the actual installation before the changeover is planned. The scope can cover support for one workstation, additional inputs and outputs or migration to a replacement control system.
Scope of the solution
- Functional description and state analysis
- PLC programming and related configuration
- Changes to sequences, diagnostics and permissions
- Software migration and I/O expansion
- Commissioning, test and handover support
- Sequence and state-exchange coordination between PLCs, robots, fixtures and adjacent handling
Engineering priorities
From operating need to design.
New functions within an existing line
An additional stopping position or conveyor branch affects logic, dependencies and displays. Changes are coordinated with documentation and operator training.
Moving to a new PLC generation
Migration covers configuration, signal connections, software, communications and tests. The effect on safety functions is assessed separately during design.
Coordinating the robot, fixture and station
Station control links part-presence confirmation, clamp positions, robot readiness and operation completion. Each step has defined exchanged states, responses to missing confirmation and conditions for continuing after interruption. Verification is coordinated with the mechanical system and robot program.
Before engineering
Inputs that matter.
- PLC type, engineering environment and backups
- Drawings, I/O list and network topology
- Fault description or required function
- Drive, HMI and higher-level interfaces
- Test scenarios, shutdown window and access
- Robot-controller interfaces, clamp sequence, tool states and cycle-recovery rules
Agreed with the proposal
Outputs and acceptance.
- Software and configuration backups for the agreed scope
- Updated functional description, changes and messages
- Test record and operator information
- Control-signal matrix and interface test scenarios covering interruption and cycle recovery
The actual scope and acceptance criteria depend on the application and contract.
From technical proposal preparation
Concrete configurations and supply scopes.
These examples describe proposed solutions and enquiry requirements. Their parameters belong to the stated project stage; completed supplies are shown separately in the project portfolio.
Offered solution
Project 0711 · 2024 · Mladá Boleslav
PLC support for an automated warehouse
Proposed support600 hours
Planned periodApril–August 2024
FocusPLC, drives, handling and diagnostics
Requirement
Support proposed for repeated workstation stops, drive diagnostics and automated handling dependencies.
Proposed solution
The proposal linked control fault analysis with operating sequence modifications. It addressed travel stops, drive diagnostic messages, handling permissions and camera-based identification. The requested scope also covered unloading manipulator behaviour at the final stacked position.
Proposed scope
- PLC and SINAMICS drive diagnostics
- Handling sequence and permission changes
- Review of camera identification and dependent steps
- Programming support in the planned period
A programming support example from an offer; 600 hours is the proposed allowance.
Discuss a similar application ↗Offered solution
Project 0532 · 2023 · Mladá Boleslav
Control and visualization for an expanded body buffer
Control layersPLC → HMI → MES
Environmentstest and production
Documentationfunctional description, I/O tests and backups
Requirement
The conveyor buffer expansion called for coordinated mechanical, PLC, HMI and manufacturing system design.
Proposed solution
The package included PLC logic changes, EcoScreen visualization updates and iTAC/DXQ integration. Server configuration and higher-level system connections addressed test and production environments and redundant servers. Software and integration formed part of a coordinated supplier scope.
Proposed scope
- PLC and related drive modifications
- HMI, messages and iTAC/DXQ connections
- Server configuration and higher-level integration
- Start-up support, training and documentation
- PLC, HMI and configuration backups
A concrete proposal for coordinated control and IT work. Related offers BC-0446 and BC-0447 addressed other buffers.
Discuss a similar application ↗Offered solution
Project 0787 · 2024 · Pardubice
Storage tank measurement renewal
Base / optional tanks10 + 6
Control systemTC700 → TC800
Specified temperature points0 / +80 / +150 °C
Requirement
Remote level, high-level and temperature measurement proposed with PLC renewal and SCADA changes.
Proposed solution
The base proposal covered ten tanks, with six additional tanks as a separate option. It included replacing TC700 with TC800, extending analogue inputs, connecting measurement loops and modifying visualization. The temperature instrumentation quotation included sensor and transmitter assembly calibration at three specified points with a supplier laboratory certificate.
Proposed scope
- Field instrumentation and related installation work
- PLC, new loops and SCADA
- New EPLAN documentation including an editable project
- Planned commissioning, process tests and training
- Arranging calibration of specified temperature assemblies
The proposed retrofit connects instruments, signals, control and documentation. Calibration points apply to the selected temperature assemblies in this proposal.
Discuss a similar application ↗Connected disciplines
Expertise for this application.
Related technologies
Connect the whole solution.
Before we start
Questions that shape the project.
Can only one part of an existing program be changed?
Yes. The boundaries and dependencies are defined first. A usable backup, appropriate access and actual wiring information are needed.
How is a return to the previous state prepared?
Backups, rollback conditions and responsibilities are agreed before the change. Hardware or mechanical changes may require additional work to reverse, so this is addressed before the shutdown.
Your next project
A clear brief.
A practical next step.
Send your drawings, operating parameters or a short description of the change you need. We will review the technical interfaces and propose the next steps towards a quotation, clarifying any missing information with you.
Discuss your requirements ↗Prepare a technical brief →+420 731 771 147info@emkoproject.cz