Services · PLC & Commissioning
From SCL to a running line
PLC programming, drives, motion, safety and site commissioning on Siemens systems — one engineer responsible from the first block of code to the last commissioning punch-list item.
Services
The unglamorous middle of every project, done properly
Anyone can quote the PLC program. The value is in the drives that tune first time, the safety chain that validates, and the serial device that finally talks.
SCL programming
S7-1500 / S7-1200 logic written in structured, version-controlled SCL with a consistent house style — sources you receive, can read, and could hand to anyone.
Motion & drives
SINAMICS S210 and G120 commissioning, Technology Objects, synchronised multi-axis gearing, torque-limited positioning, absolute-encoder homing strategies.
Safety
Fail-safe CPUs, PROFIsafe drive integration, STO/SS1, and safety chains traced end-to-end — engineered and documented, not bolted on.
Networks & devices
PROFINET architecture, OPC UA, IO-Link sensors, and the awkward serial devices nobody else wants to integrate — RS232/485 protocols reverse-engineered and made reliable.
Robot integration
Collaborative and industrial robots tied into the cell over PROFINET and TCP — handshaking, safety interlocks and sequence coordination with the PLC.
Site commissioning
Guided startups, drive tuning, fault-finding and FAT/SAT — on site until production actually runs, with the documentation to prove it.
Case studies
Recent work, names withheld
Client details available on request. Full write-ups on the case-studies page.
Robotic welding cell · South Australia
A complete welding cell delivered as one scope: a collaborative robot carrying the torch, a servo positioner rotating the workpiece, and three synchronised servo clamps centring it — all coordinated by a single fail-safe S7-1500 Technology CPU.
The cell mixes the things that usually need three contractors: multi-axis motion with torque-limited contact detection, a PROFIsafe safety chain through to drive STO, robot handshaking over TCP, induction heating integrated over RS232, and WinCC Unified faceplates for the operators. One integrator wrote, wired and commissioned all of it.
Outcome: logic, motion, safety, HMI and commissioning delivered by one party — no interface gaps, one phone number when something needs changing.
- Controller
- S7-1500 Technology + Fail-safe CPU
- Robot
- Collaborative arm over PROFINET + TCP
- Motion
- 3-axis synchronised servo clamping, torque-limited contact detection
- Positioning
- Servo rotary positioner with absolute-encoder homing
- Safety
- PROFIsafe chain: E-stop → F-CPU → drive STO/SS1
- Integration
- Serial-connected induction heating, IO-Link sensing, WinCC Unified faceplates
Palletising fleet, 13 robot cells · pasta production, South Australia
- Scale
- 13 robot palletising cells across the packing lines
- Controller
- S7-1500 F-CPU
- Safety
- PROFIsafe zones per cell — gate access, light curtains, safe stops
- Sensing
- IO-Link sensors and valve terminals with diagnostics back to the PLC
- Robots
- Palletising robots integrated over PROFINET
- HMI
- Line dashboards and shift KPI reporting in WinCC Unified
End-of-line palletising for a high-volume pasta plant: thirteen robot cells taking cartons off the packing lines, each cell with its own PROFIsafe safety zone — gate access, light curtains and safe stops — so one cell can be entered while its neighbours keep running.
Fail-safe S7-1500 logic coordinates the fleet, IO-Link gives every sensor and valve terminal a diagnostic voice, and WinCC Unified dashboards report live throughput and shift KPIs for every line on one screen.
Outcome: commissioned cell by cell around live production — the plant never stopped packing while the fleet went in.
Read the full case study →Feedback
What clients say
Every machine on one screen, live. Our supervisors stopped walking the floor to find problems — the dashboard finds them first.
Thirteen cells commissioned one by one around a running plant. We never lost a shift to the upgrade.
When something stops at 2 am, the KPI screens tell night shift exactly where to look before they pick up the phone.
How we work
What you get with the invoice
Fixed-scope quotes
A clear statement of what is included, priced as a job — not an open-ended day rate.
Sources handed over
All SCL sources, HMI projects and configuration are yours, documented and version-controlled.
Documentation included
Functional descriptions, IO lists and commissioning records — written as we go, not reconstructed after.
Support that answers
Remote and on-site support from the engineer who wrote the code, not a ticket queue.
Have a machine that needs a brain?
Greenfield cell, retrofit, or a half-finished project someone else walked away from — describe it and we'll quote it straight.
Scope a project