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PLC Programming for Special-Purpose Machines and Conveyor Systems_

DS Auto-Solutions delivers PLC programming and commissioning for special-purpose machines and conveyor systems

PLC Programming

PLC programming for special-purpose machines and conveyor systems

We develop PLC programs and HMI visualizations using Siemens Step 7 Classic and the TIA Portal as well as Beckhoff TwinCAT 2/3 with WinCC. Programming languages: LAD, FBD, STL, SCL, ST, and S7-Graph. We structure the sequence control, integrate sensors, drives, and safety, and handle on-site commissioning.

Core Capabilities

  • PLC programming: Siemens Step 7 Classic, TIA Portal, and Beckhoff TwinCAT 2/3

  • HMI/WinCC: faceplates, recipes, user/role management, alarm system

  • Sequence control: S7-Graph, state-based sequences, clearly structured FB/FC architecture

  • Fieldbus & interfaces: Profinet, Profibus, EtherCAT, OPC UA; integration of scanners, robots, SCADA/MES

  • Diagnostics & data: alarm system, trace/trend, data logging for fast troubleshooting

  • Safety: F-CPU, safe I/Os, enabling switch, performance level verification

  • Software quality: UDTs and standards, naming conventions, version control, code reviews, testing (FAT/SAT)

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PLC Programming
WinCC HMI of the DS-Place: machine overview with tabs and status indicators

HMI Programming / Machine Visualization

We create plant visualizations with WinCC in the TIA Portal: standardized faceplates, clear alarm management and diagnostics down to signal level. For DS-Place and customer systems we use reusable screens and templates so operators can quickly access statuses, faults and recipes. Language switching (DE/EN), user and role management, trend/trace, manual mode per unit as well as overview and detail pages are standard. Where required, we integrate scanners, robots, cameras (e.g. Keyence) and MES/OPC UA — including unambiguous status and error codes.

HMI scope of services

  • WinCC (TIA Portal): Comfort/Advanced, project-specific screen hierarchy

  • Faceplates & standards: consistent controls, symbols, colors

  • Alarm system: priorities, acknowledgements, cause/remedy texts

  • Diagnostics: channel/drive diagnostics, trend/trace, screenshot/export

  • Recipes: format/product parameters, management, optional audit trail

  • User management: roles, password policies, log

  • Interfaces: Profinet, OPC UA, robots/scanners/Keyence camera

  • Documentation & handover: tag lists, screen index, operating manual

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Frequency Inverter Setup

We commission frequency inverters and axes on the PLC side: SEW Movidrive (incl. modulo/bus positioning), Danfoss FC series, Siemens Sinamics G120/S120, and drive controllers such as CU320. We implement parameterization, telegrams/process data, homing/reference runs, and interlock chains project-specifically — including cycle/positioning tasks and diagnostics via Profinet/EtherCAT. Project examples: modulo positioning on rotary index tables, line axes with Beckhoff AX5000 (coupled virtual axis), and speed-controlled pumps/drives.

Our Services Include:

  • Parameterization & telegrams: SEW Movidrive/Movitrac, Danfoss FC-302, Sinamics G120/S120.

  • Function blocks: FC/FB blocks for drive control, setpoint/status, fault handling.

  • Positioning & cycle tasks: modulo positioning, bus positioning, rotary index/turntable operation.

  • Linear axes: AX5000 cascaded/virtual axis, homing runs, end-position logic.

  • Fieldbus & interfaces: Profinet, EtherCAT, Profibus — clean integration into PLC sequences.

  • Acceptance: parameter documentation, trace/trend, FAT/SAT, and on-site commissioning.

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