Advanced PLC Programming and Integration of Complex Industrial Systems
We specialize in the development of software solutions and commissioning of complex systems – from individual stations to complete, networked automated lines.
What sets ENSO apart is the rich experience of our engineers who have spent years in the field throughout Germany, directly participating in the most demanding projects within the German automotive industry. Deep process knowledge in the plants of giants such as BMW and VW has enabled us to implement the highest standards of precision, reliability and efficiency in our work. With many years of expertise in the Siemens (TIA Portal) and Beckhoff (TwinCAT 3) ecosystems, we bring proven German engineering quality tailored to your specific needs to your production.
Our Solutions for your Production
Automation of Production Processes
We help you transition from manual processes to fully automated solutions. Whether you are planning to upgrade an existing line or build a completely new system, ENSO offers expert advice and turnkey technical implementation.
- Engineering & Consulting: Based on your input parameters, we design the optimal solution, select the appropriate technology and define the control architecture.
- Compliance with EU standards: All our solutions are designed strictly according to the Machinery Directive (2006/42/EC). This means that we take into account the safety standards, ergonomics and legal obligations that your equipment must meet right from the start.
- Standardized approach: By applying the rules of the profession and our internal standards, we ensure that the system is long-lasting, robust and easy to maintain.
Cycle Time Optimization and Acceleration
You have a functional line, but need more capacity? We specialize in analyzing and “unlocking” the hidden potentials of your existing systems. If you have up-to-date documentation (EPLAN diagrams) and up-to-date software, we can significantly increase the efficiency of your production without having to invest in completely new lines.
Our optimization approach includes:
- Bottleneck Analysis: We identify exactly which cell or operation slows down the whole process.
- Hardware Upgrade: We propose and implement targeted improvements – from faster drive systems (servomotors) and sensors with shorter response times to the installation of new elements such as buffer conveyors or advanced robotic grippers.
- Software Optimization: We redesign the PLC code using advanced algorithms for parallel execution of operations, shorten communication cycles and optimize the trajectories of manipulators and robots.
Result: We achieve stable acceleration of the production process, reduce the cost per unit produced, and extend the life of your equipment through smarter resource management.
Control System Retrofit and Modernization
We perform complete modernization and retrofit of machines in which the mechanical part is correct, but the control system is outdated. Our PLC control change includes software migration, installation of new sensors, and optimization of machine cycle time, thus giving old equipment the performance of modern lines.
Often, mechanically correct machines become a bottleneck due to outdated electronics. Our specialty is the retrofit of the machine, which includes:
- PLC Control Upgrade: Replacement of old and unreliable systems (such as Siemens S7-200 or S7-300) with the latest controllers.
- Software Migration: Secure logic transfer with code optimization for faster operation.
- Adding new features: Implementation of modern sensors, measuring systems and remote access for faster diagnostics.
- HMI visualization for operators: Creation of intuitive machine control screens with all relevant data that allows any problem to be solved through the panel without the need to physically connect the laptop to the PLC.
Implementation of Safety Systems
As part of the automation of production processes, we pay special attention to occupational safety systems. We design and implement complete security solutions that include:
- Presence detection systems: Integration of safety light curtains and safety switch mats to protect danger zones.
- Control elements: Implementation of two-hand controls , safety foot switches and Dead man’s switch devices for safe operation in the vicinity of the machine.
- Advanced Protection: Installation of interlocking safety locks, laser space scanners and emergency stop systems (E-Stop).
- Fail-safe communication: Application of modern protocols such as PROFIsafe for reliable transmission of security signals over the network.
- Implementation of safety protocols for PLC.
LOTO / LOTOTO Protocols
We pay special attention to the preparation of machines for safe maintenance. Our systems support strict LOTO (Lockout-Tagout) and LOTOTO (Lockout-Tagout-Tryout) procedures, ensuring that any energy on the machine can be safely isolated and verified before any intervention.
Customer Value
By implementing our solutions, you ensure:
Technology Standard: Siemens & Beckhoff
Siemens TIA Portal: Standardization and ENSO Standard
Our approach to Siemens platforms (S7-1200, S7-1500, HMI panels) is based on maximum automation of the programming process itself. We have developed an internal ENSO standard for PLC and HMI that allows us to achieve superior precision and speed of implementation:
Beckhoff TwinCAT 3: Ultra-Fast Motion Control
While we use Siemens for robust and complex lines, we choose the Beckhoff platform for projects that require extreme speed and precise synchronization. Thanks to the architecture of an industrial PC and a cycle time that is many times faster than standard PLC controllers, we achieve results that were unimaginable until recently.
List of Completed Projects
The following is a brief overview of several realized PLC programming projects.
Element Logic (Unna – Germany) – Intelligent Transport System for Distribution Centers
For the client Element Logic, we participated in an extensive project of designing, engineering and programming a parcel transport line. The project included complete engineering – from the creation of electrical documentation in EPLAN to complex PLC programming.
Technical specification of the system:
- Control platform: Siemens S7-1500F (Fail-safe) PLC with distributed peripherals ET200SP.
- Network architecture: An extremely complex Profinet network with over 200 active devices (Elinx drivers for conveyors), which required advanced optimization of the communication clock.
- Design: Creation of a complete electrical scheme in EPLAN and development of a software standard in cooperation with the client’s engineering team.
Key technical challenges and solutions:
- Safety: Implementation of local Notaus and connection to other lines via the ProfiSafe protocol on Ethernet.
- Communication optimization: Due to the huge amount of data from 200+ Profinet devices, the initial PLC cycle time of the system was 150 ms. We carried out an in-depth optimization of Profinet data reading, which drastically shortened the PLC cycle time and ensured stable and fast line response.
- Integration and standardization: We participated in the creation of a global software standard for the client, ensuring modularity and easier maintenance of future systems.
Result:
Delivery of a turnkey system that seamlessly controls the flow of packaging (empty and full boxes) in a high-frequency logistics environment, with the highest level of network and process security.
DW Reusables (Hum na Sutli, Croatia) – Modernization of the Palletizing Line
For the client DW Reusables, a leading manufacturer of returnable packaging, we successfully executed a complete control system replacement project on a bottle and crate handling line. The project focus was on increasing system reliability and reducing downtime.
Technical specification of the system:
- Control platform: Implementation of a modern Siemens S7-1215 controller within the TIA Portal environment.
- Safety: Implementation of light curtains and E-stops.
- Line Architecture: The system is divided into 4 technological segments, synchronized with each other for a continuous flow of materials:
- Depalletizing: Two entrance segments in charge of receiving and delivering empty crates and bottles.
- Filling the crates: Central segment for automatic loading of bottles into crates.
- Palletizing: An outlet segment that stacks full crates on pallets, storing them for further transport.
Key advantages and realization:
- Retrofit and modernization: By replacing the old control with the new Siemens platform, we have enabled the client more accurate diagnostics and easier system maintenance.
- Synchronization of segments: Special emphasis is placed on optimizing the speed of the line.
BMW, (Dingolfing – Germany) – Battery Assembly Line
We participated in a complex project of programming and commissioning an automated line for the production of high-voltage batteries. The work on this project included the implementation of the strictest BMW standards (TMO 3) within the TIA Portal.
Technical specification and system architecture:
- Control platform: The system is based on Siemens S7-1500 controllers (ET200pro version for stations and the more powerful S7-1500 for Master PLC).
- Verkettung (Network Integration): Implementation of communication between the main PLC and individual stations via standardized interfaces (Verkettung Schnittstelle).
- Technological process: Programming of the robotic laser welding station (Potentiallasche) to the battery module.
Key functionalities and implementation:
- Precise positioning: Use of Keyence laser sensors to verify the position of the workpiece carrier (Werkstückträger) before fixing and starting the process.
- Advanced Motion Control: Control of a three-axis manipulator integrated with an IPG laser welder for high-precision welding.
- Safety & Profisafe: Implementation of a complete safety net. The system included Not-Aus monitoring of neighboring stations, ensuring an immediate stop of the entire segment in the event of an emergency.
- Process monitoring: Development of logic for verification of contact arc establishment (plausibility of response within 500ms) with feedback signaling, thus ensuring maximum weld quality and reduction of scrap.
Our contribution:
In addition to the programming according to the TMO 3 standard, the ENSO team was instrumental in the commissioning phase and subsequent software upgrades and cycle time optimisations of the station, ensuring flawless operation at the heart of BMW’s e-mobility production.
Valeo Siemens (Veszprém – Hungary) – Integration of Complex Lines for Mercedes and VW
The engagement on the project in Veszprém included the programming and commissioning of four high-tech lines for the production of electric vehicle components. Our focus was on synchronizing the main control system with a number of specialized units within the production process.
Technical architecture and platform:
- Management structure: “Master-Slave” architecture system with central Siemens S7-1517F processor and distributed intelligence on stations with S7-1512SP controllers.
- Process operations: The lines integrated a wide range of operations: plasma cleaning, robotic pick-and-place, automatic screw clamping, pressing, adhesive application and precise optical control.
Expertise in device integration:
A key part of our work was to program the sequences and ensure seamless communication and handshake between the PLC and a variety of equipment from different manufacturers:
- Robotic systems and vision sensors: Integration of cameras and QR code readers for traceability and quality control. Commissioning of the scara robot for tightening screws.
- Measuring equipment: Implementation of measuring equipment for leak testing and complex electrical tests.
- Communication protocols: Development of robust control interfaces – from sending start commands to precise processing of status signals (Done, Error, Busy) in real time.
Clock optimization and efficiency:
Special emphasis is placed on cycle time optimization. Through a detailed analysis of communication jams and parallelization of process steps, we have ensured maximum line throughput while maintaining the highest quality standards prescribed by Mercedes and VW.
EGO Elektro-komponente (Zagreb – Croatia) – Design and Automation of the Rod Regulator Assembly Machine
This project included a complete solution – from system design to PLC program development and commissioning of a specialized machine for assembling the main prop. The machine is designed as a highly productive unit with a rotary table that combines several different technological processes.
Technical specification of the system:
- Control platform: The system is controlled by a Siemens S7-300 series PLC in combination with an operating panel (HMI) for intuitive visualization and parameter control.
- Drive solutions: The main movement is carried out by a precise rotary table driven by an electric motor, while the individual process stations are equipped with pneumatic manipulators.
- Integration of technologies: Various systems within the line were successfully connected and synchronized, including a welding unit (welder) and a machine vision system (camera) for quality checking.
Key functionalities:
- Multi-Process Stations: Automated execution of a series of operations: loading of components, assembly, jamming, riveting and welding.
- Traceability and Monitoring (Data Tracking): An advanced data monitoring system is implemented for each operation. The PLC monitors and records the statuses for each individual nest on the turntable, ensuring full control over the assembly and verification process.
- Quality Control: The integration of sensors and cameras allows automatic verification of each phase of operation, thus eliminating the possibility of error in the final product.
General Electric (Hungary) – Automation of Furnaces for Heat Treatment of Turbine Engine Components
This project included the development of a control system for the annealing process of high-precision steel parts. Due to the complexity of the industry, the focus was on temperature stability and archiving of process data.
Technical specifications and functionalities:
- Control platform: The system is based on the Siemens S7-300 platform
- Precise temperature control: Implementation of advanced algorithms for the regulation of thermal power, ensuring uniform annealing and strict adherence to the set temperature curves.
- Logistics Transport: Full automation of the transport trolley for the entry and exit of materials, integrated with the furnace door safety system.
Data management and HMI:
- Data Logging Reporting: A system for continuous recording and storage of process data has been developed. Each annealing cycle has its own digital record, which is crucial for traceability in the aerospace and energy industries.
- User Interface (HMI): Creation of an intuitive control panel program that allows the operator to monitor all parameters in real time, manage recipes and view historical temperature trends.
Magna (Graz – Austria) – Automation of the body roof assembly line – “MINI” (Automotive)
Realization of a complete solution for the preparation and assembly of roof body segments on an automated line for the “MINI” brand. The project required the integration of various communication protocols and precise coordination of the robot cells with the transport system.
Technical architecture and management:
- Control management: The system is based on the powerful Siemens S7-400 series of PLCs, designed to control a large number of inputs/outputs and complex processes.
- Advanced visualization: Implementation of the WinCC system on industrial computers for detailed line monitoring, diagnostics and management of production parameters in real time.
- Built-in security: The safety functions of the entire range are entrusted to the specialized PILZ Safety PLC, ensuring the highest level of protection in the robotic environment.
Communication network and peripherals:
- Interbus Fiber Optic Infrastructure: All key actuators, including SEW frequency inverters and KUKA robots, are connected to the PLC via the Interbus network using optical fibers. This ensures complete immunity to electromagnetic interference and exceptional data transmission speed over long distances.
- Robotic integration: Coordination of KUKA robots in the tasks of manipulation, spot welding and precise application of adhesive to the body.
- Transport logistics: Control of a system of moving rollers and precise body positioning tables, thus achieving maximum synchronization between stations.
