PLC programming and control technology
The brain of smart purpose-built machines and production lines
The mechanics of a modern industrial machine provide the muscle, but the PLC (Programmable Logic Controller) is the brain that brings the system to life, moves it, coordinates it and makes it efficient. At our Jászberény center, our engineers program the controls with a comprehensive systems approach so that the production cells meet the highest Industry 4.0 expectations.
Whether it's a newly designed target machine, the modernization of existing systems, or the coordination of complex robot cells, Konkoly Electro's PLC programmers create logic that guarantees predictable, safe, and data-driven operation.
Focus on functional machine safety (Safety PLC)
Even the most sophisticated production process is only worth something if the operators can work in complete safety. Therefore, the zero step of control technology is safety:
- Verifiable reliability: Safety functions are integrated into the control in such a way that their reliability can be calculated and verified, for example according to Performance Level, PL, based on EN ISO 13849-1.
- Safety PLC integration: We also monitor everyday but critical details such as the locking of the protective door, two-hand start, or the STO (Safe Torque Off) motion stop logic. The above elements make the machine more predictable in operation, and its validation is much simpler. And the CE conformity documentation is almost spontaneously created during development, it does not have to be added to the concept afterwards.
Energy efficiency at the code level
With today's energy prices and ESG expectations, every kilowatt hour counts. At the level of PLC programming, energy-efficient machine design means that the machine does not run auxiliary systems unnecessarily, essentially has no idle speed. We design controls and PLC programs that, in addition to maintaining the necessary technological parameters, also pay attention to automatically switching off or putting into standby mode those modules that are not needed in a given phase.
Data-driven manufacturing: deterministic evaluation and ERP/MES integration
Modern purpose-built machines no longer operate in isolation; deterministic evaluation and traceable data are required in almost every process.
- Real-time monitoring: Our PLCs continuously collect cycle times, measure scrap data and monitor energy consumption, supporting ESG reporting, among other things.
- Enterprise management connection: Measurement data can be immediately fed into the MES or ERP system, so the reasons for scrap are immediately clear, without having to be deciphered later. This level of transparency significantly facilitates predictive maintenance and reduces the number of unexpected downtimes.
Programming in the shadow of the digital twin
It is not during the on-site installation that you find out if something is not perfect. During virtual testing, we refine cycle times, PLC and robot programming logic, and even think about how production data will be fed into the enterprise management system. By the time the machine is physically assembled, the PLC code is already based on a solid logic that has been thoroughly tested in advance using digital twin technology. This means that during on-site installation, there is no need to improvise or redesign, but only to physically build a pre-tested solution.
Do you expect more from your machines than mechanical movement?
Choose intelligent, safe and data-based control! Whether it's a new investment or the Industry 4.0 integration of your existing machinery, you can always count on Konkoly Electro's experienced PLC programmers. Request a consultation, let's make your production more transparent!