{"id":384,"date":"2016-04-23T11:56:33","date_gmt":"2016-04-23T11:56:33","guid":{"rendered":"http:\/\/enso.hr\/en\/?page_id=384"},"modified":"2026-05-08T06:26:52","modified_gmt":"2026-05-08T06:26:52","slug":"plc-programming","status":"publish","type":"page","link":"https:\/\/enso.hr\/en\/plc-programming\/","title":{"rendered":"PLC Programming of Production Lines and Machines"},"content":{"rendered":"\n
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Advanced PLC Programming and Integration of Complex Industrial Systems<\/h2>\n\n\n\n

We specialize in the development of software solutions and commissioning of complex systems \u2013 from individual stations to complete, networked automated lines.<\/p>\n\n\n\n

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.<\/strong> 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)<\/strong> and Beckhoff (TwinCAT 3)<\/strong> ecosystems, we bring proven German engineering quality tailored to your specific needs to your production. <\/p>\n<\/div>\n\n\n\n

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Our Solutions for your Production<\/h2>\n\n\n\n
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Automation of Production Processes<\/h3>\n\n\n\n
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We help you transition from manual processes to fully automated solutions<\/strong>. Whether you are planning to upgrade an existing line or build a completely new system, ENSO offers expert advice and turnkey technical implementation. <\/p>\n\n\n\n

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  • Engineering & Consulting:<\/strong> Based on your input parameters, we design the optimal solution, select the appropriate technology and define the control architecture.<\/li>\n\n\n\n
  • Compliance with EU standards:<\/strong> All our solutions are designed strictly according to the Machinery Directive (2006\/42\/EC).<\/strong> This means that we take into account the safety standards, ergonomics and legal obligations that your equipment must meet right from the start. <\/li>\n\n\n\n
  • Standardized approach:<\/strong> By applying the rules of the profession and our internal standards, we ensure that the system is long-lasting, robust and easy to maintain.<\/li>\n<\/ul>\n<\/div>\n\n\n\n
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    Cycle Time Optimization and Acceleration<\/h3>\n\n\n\n
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    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<\/strong>) and up-to-date software, we can significantly increase the efficiency of your production without having to invest in completely new lines. <\/p>\n\n\n\n

    Our optimization approach includes:<\/p>\n\n\n\n

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    • Bottleneck Analysis:<\/strong> We identify exactly which cell or operation slows down the whole process.<\/li>\n\n\n\n
    • Hardware Upgrade:<\/strong> We propose and implement targeted improvements \u2013 from faster drive systems (servomotors)<\/strong> and sensors with shorter response times to the installation of new elements such as buffer conveyors<\/strong> or advanced robotic grippers.<\/li>\n\n\n\n
    • Software Optimization:<\/strong> We redesign the PLC code using advanced algorithms for parallel execution of operations, shorten communication cycles and optimize the trajectories of manipulators and robots.<\/li>\n<\/ul>\n\n\n\n

      Result:<\/strong> 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.<\/p>\n<\/div>\n\n\n\n

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      Control System Retrofit and Modernization<\/h3>\n\n\n\n
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      We perform complete modernization and retrofit of machines<\/strong> in which the mechanical part is correct, but the control system is outdated. Our PLC control change<\/strong> includes software migration, installation of new sensors, and optimization of machine cycle time, thus giving old equipment the performance of modern lines. <\/p>\n\n\n\n

      Often, mechanically correct machines become a bottleneck due to outdated electronics. Our specialty is the retrofit of the machine<\/strong>, which includes: <\/p>\n\n\n\n

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      • PLC Control Upgrade:<\/strong> Replacement of old and unreliable systems (such as Siemens S7-200 or S7-300) with the latest controllers.<\/li>\n\n\n\n
      • Software Migration:<\/strong> Secure logic transfer with code optimization for faster operation.<\/li>\n\n\n\n
      • Adding new features:<\/strong> Implementation of modern sensors, measuring systems and remote access for faster diagnostics.<\/li>\n\n\n\n
      • HMI visualization for operators<\/strong>: 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.<\/li>\n<\/ul>\n<\/div>\n\n\n\n
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        Implementation of Safety Systems<\/h3>\n\n\n\n
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        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: <\/p>\n\n\n\n

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        • Presence detection systems:<\/strong> Integration of safety light<\/strong> curtains and safety switch mats<\/strong> to protect danger zones.<\/li>\n\n\n\n
        • Control elements:<\/strong> Implementation of two-hand controls<\/strong> , safety foot switches<\/strong> and Dead man’s switch<\/strong> devices for safe operation in the vicinity of the machine.<\/li>\n\n\n\n
        • Advanced Protection:<\/strong> Installation of interlocking safety locks, laser space scanners and emergency stop systems (E-Stop).<\/li>\n\n\n\n
        • Fail-safe communication:<\/strong> Application of modern protocols such as PROFIsafe<\/strong> for reliable transmission of security signals over the network.<\/li>\n\n\n\n
        • Implementation of safety protocols for PLC.<\/li>\n<\/ul>\n\n\n\n

          LOTO \/ LOTOTO Protocols<\/strong><\/h4>\n\n\n\n

          We pay special attention to the preparation of machines for safe maintenance. Our systems support strict LOTO (Lockout-Tagout)<\/strong> and LOTOTO (Lockout-Tagout-Tryout)<\/strong> procedures, ensuring that any energy on the machine can be safely isolated and verified before any intervention. <\/p>\n<\/div>\n<\/div>\n<\/div><\/section>\n\n\n\n

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          Customer Value<\/h2>\n\n\n\n

          By implementing our solutions, you ensure:<\/p>\n\n\n\n

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          Maximum Productivity<\/strong><\/strong><\/strong><\/strong><\/h3><\/div><\/div>

          Elimination of bottlenecks and optimization of each step of the process contributes to faster cycle time<\/p><\/div><\/div>\n\n\n\n

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          High Reproducibility and Quality<\/strong><\/strong><\/strong><\/strong><\/strong><\/h3><\/div><\/div>

          Each product is identical, without variations caused by the human factor with the integration of quality monitoring systems and production statistics<\/p><\/div><\/div>\n\n\n\n

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          New Features<\/strong><\/strong><\/strong><\/strong><\/strong><\/strong> for Old Lines<\/h3><\/div><\/div>

          Retrofits of old lines usually bring new features that were not easy to implement before.<\/p><\/div><\/div>\n\n\n\n

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          Safe Machines<\/h3><\/div><\/div>

          Integration of safety systems in accordance with legal regulations for safe and stable operation of machines.<\/p><\/div><\/div>\n<\/div>\n<\/div><\/section>\n\n\n\n

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          Technology Standard: Siemens & Beckhoff<\/h2>\n\n\n\n
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          Siemens TIA Portal: Standardization and ENSO Standard<\/h3>\n\n\n\n

          Our approach to Siemens platforms (S7-1200, S7-1500, HMI panels<\/strong>) is based on maximum automation of the programming process itself. We have developed an internal ENSO standard<\/strong> for PLC and HMI that allows us to achieve superior precision and speed of implementation: <\/p>\n\n\n\n

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          Automatic Data Import<\/strong><\/strong><\/strong><\/h4><\/div><\/div>

          We start programming by directly exporting the IO sheet from EPLAN<\/strong> to the TIA Portal, thus eliminating human error at the earliest stage of the project.<\/p><\/div><\/div>\n\n\n\n

          Modularity and SCL Architecture<\/strong><\/strong><\/strong><\/strong><\/h4><\/div><\/div>

          Our function blocks (FB) are developed in SCL language<\/strong> and are part of our “ENSO Global” library. For the end application, the block is ready for drag-and-drop in FBD or Ladder diagrams, where we focus solely on parameterization. <\/p><\/div><\/div>\n\n\n\n

          Automatic Notification Generation<\/strong><\/strong><\/strong><\/h4><\/div><\/div>

          We use the technology of automatically pulling notification texts from the PLC to the HMI. Given that our systems often have over 1,000 notifications<\/strong>, this approach guarantees 100% accuracy of information and drastically shortens the time it takes to get up and running. <\/p><\/div><\/div>\n\n\n\n

          Visual Monitoring and Real-time Notifications<\/strong><\/strong><\/h4><\/div><\/div>

          We develop intuitive HMI interfaces that display complex logic in the background in a simple and visually clear way \u2013 from the exact position of each drive and cylinder to a detailed system of notifications for elements (faults, warnings and information) and detailed machine operation sequences.<\/p><\/div><\/div>\n<\/div>\n<\/div>\n\n\n\n

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          Beckhoff TwinCAT 3: Ultra-Fast Motion Control<\/h3>\n\n\n\n

          While we use Siemens for robust and complex lines, we choose the Beckhoff<\/strong> 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. <\/p>\n\n\n\n

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          Advanced Electronic Camming<\/strong><\/strong><\/h4><\/div><\/div>

          We specialize in the implementation of complex “Electronic Camming” systems. Our solutions replace outdated mechanical systems, allowing for greater flexibility and drastically higher production speeds. <\/p><\/div><\/div>\n\n\n\n

          Speed without Competition<\/strong><\/strong><\/strong><\/h4><\/div><\/div>

          On projects for the production of springs, using Beckhoff control, converters and servo drives, we accelerate the machine speed <\/strong>and raise the capacity of the machine from mechanical 100 to an incredible 250 pieces per minute<\/strong>.<\/p><\/div><\/div>\n\n\n\n

          PC-Based Control Advantage<\/strong><\/h4><\/div><\/div>

          Using the processing power of an industrial computer allows us to process complex algorithms in real time while maintaining minimal jitter<\/em>.<\/p><\/div><\/div>\n\n\n\n

          EtherCAT Integration<\/strong><\/strong><\/h4><\/div><\/div>

          We make the most of EtherCAT communication for ultra-fast peripheral response.<\/p><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div><\/section>\n\n\n\n

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          List of Completed Projects<\/h2>\n\n\n\n

          The following is a brief overview of several realized PLC programming projects.<\/p>\n\n\n\n

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          Element Logic (Unna – Germany) \u2013 Intelligent Transport System for Distribution Centers<\/h3>\n<\/div>\n\n\n\n
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          For the client Element Logic<\/strong>, we participated in an extensive project of designing, engineering and programming a parcel transport line. The project included complete engineering \u2013 from the creation of electrical documentation in EPLAN<\/strong> to complex PLC programming. <\/p>\n\n\n\n

          Technical specification of the system:<\/strong><\/h4>\n\n\n\n
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          • Control platform:<\/strong> Siemens S7-1500F (Fail-safe)<\/strong> PLC with distributed peripherals ET200SP<\/strong>.<\/li>\n\n\n\n
          • Network architecture:<\/strong> An extremely complex Profinet network with over 200 active devices<\/strong> (Elinx drivers for conveyors), which required advanced optimization of the communication clock.<\/li>\n\n\n\n
          • Design:<\/strong> Creation of a complete electrical scheme in EPLAN<\/strong> and development of a software standard in cooperation with the client’s engineering team.<\/li>\n<\/ul>\n\n\n\n

            Key technical challenges and solutions:<\/strong><\/h4>\n\n\n\n
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            • Safety:<\/strong> Implementation of local Notaus and connection to other lines via the ProfiSafe protocol on Ethernet<\/strong>.<\/li>\n\n\n\n
            • Communication optimization:<\/strong> 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<\/strong>, which drastically shortened the PLC cycle time and ensured stable and fast line response.<\/li>\n\n\n\n
            • Integration and standardization:<\/strong> We participated in the creation of a global software standard for the client, ensuring modularity and easier maintenance of future systems.<\/li>\n<\/ul>\n\n\n\n

              Result:<\/strong><\/h4>\n\n\n\n

              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.<\/p>\n\n\n\n

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              Package transport line<\/figcaption><\/figure>\n<\/figure>\n<\/div>\n<\/div><\/article>\n\n\n\n
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              DW Reusables (Hum na Sutli, Croatia) \u2013 Modernization of the Palletizing Line<\/h3>\n<\/div>\n\n\n\n
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              For the client DW Reusables<\/strong>, 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. <\/p>\n\n\n\n

              Technical specification of the system:<\/strong><\/h4>\n\n\n\n
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              • Control platform:<\/strong> Implementation of a modern Siemens S7-1215<\/strong> controller within the TIA Portal<\/strong> environment.<\/li>\n\n\n\n
              • Safety:<\/strong> Implementation of light curtains and E-stops.<\/li>\n\n\n\n
              • Line Architecture:<\/strong> The system is divided into 4 technological segments, synchronized with each other for a continuous flow of materials:\n
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                • Depalletizing:<\/strong> Two entrance segments in charge of receiving and delivering empty crates and bottles.<\/li>\n\n\n\n
                • Filling the crates:<\/strong> Central segment for automatic loading of bottles into crates.<\/li>\n\n\n\n
                • Palletizing:<\/strong> An outlet segment that stacks full crates on pallets, storing them for further transport.<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n\n\n\n

                  Key advantages and realization:<\/strong><\/h4>\n\n\n\n
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                  • Retrofit and modernization:<\/strong> By replacing the old control with the new Siemens platform, we have enabled the client more accurate diagnostics and easier system maintenance.<\/li>\n\n\n\n
                  • Synchronization of segments:<\/strong> Special emphasis is placed on optimizing the speed of the line.<\/li>\n<\/ul>\n\n\n\n
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                    \"ENSO
                    Bottles package line<\/figcaption><\/figure>\n\n\n\n
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                    Bottles package line.<\/figcaption><\/figure>\n<\/figure>\n<\/div>\n<\/div><\/article>\n\n\n\n
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                    BMW, (Dingolfing – Germany) \u2013 Battery Assembly Line<\/h3>\n<\/div>\n\n\n\n
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                    \"BMW<\/figure>\n<\/div>\n<\/div>\n\n\n\n

                    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<\/strong>) within the TIA Portal<\/strong>. <\/p>\n\n\n\n

                    Technical specification and system architecture:<\/strong><\/h4>\n\n\n\n
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                    • Control platform:<\/strong> The system is based on Siemens S7-1500<\/strong> controllers (ET200pro version for stations and the more powerful S7-1500 for Master PLC).<\/li>\n\n\n\n
                    • Verkettung (Network Integration):<\/strong> Implementation of communication between the main PLC and individual stations via standardized interfaces (Verkettung Schnittstelle<\/em>).<\/li>\n\n\n\n
                    • Technological process:<\/strong> Programming of the robotic laser welding station (Potentiallasche<\/em>) to the battery module.<\/li>\n<\/ul>\n\n\n\n

                      Key functionalities and implementation:<\/strong><\/h4>\n\n\n\n