Controls

Our team holds extensive expertise in industrial automation with deep experience in Programmable Logic Controllers (PLCs), spanning across various OEMs and architectures. We specialize in the design, development, and deployment of motion control, sequencing, and device interfacing logic using leading PLC platforms. Our capabilities include:

PLC Platforms

Mitsubishi PLCs

• Q-Series, IQ-R Series, FX5U/FX3U Series
• Software: GX IEC Developer, GX Works2, GX Works3

Allen-Bradley PLCs

• RSLogix 5000, ControlLogix 1756 series

Siemens PLCs

• S7-1200, S7-1500
• Software: TIA Portal V16/V17

Modules & Protocols Handled

• Mitsubishi: QJ71E71 (Ethernet), MODBUS(Master\Slave) modules, ENZTR (scanner), CC-Link
• Siemens: Scalance X2B
• AB: Ethernet/IP, MSG instructions
• Communication: MODBUS RTU, MODBUS TCP, RS-485, Ethernet/IP, HTTP

Programming Languages

Ladder Logic (LD) – widely used for discrete control, relay logic replacement, and sequential processes

Structured Text (ST) – used for mathematical computations, string processing, and complex algorithmic control

Function Block Diagram (FBD) – ideal for motion control, PID regulation, and reusable modular control

Sequential Function Chart (SFC) – for step-by-step process flow and state-based automation

Control & Integration

• Real-time data acquisition from PLCs and intelligent modules (temperature, load cell, scanner, etc.)
• Bi-directional control from customer-developed applications written in Python, C++, C#, etc.
• Implemented custom APIs and protocol handlers for seamless interaction between PLC and client SCADA/HMI/MES systems

This multi-layer integration approach allows us to bridge OT (Operational Technology) and IT (Information Technology), ensuring unified control, monitoring, and traceability.

Project Implementation on

Vehicle Color Grouping Logic – Mitsubishi Q-Series PLC

• Designed logic to group incoming vehicles based on color codes read from SKID
• Automated dynamic routing and paint booth sequencing
• Implemented real-time vehicle location tracking in the buffer
• Achieved ~90% efficiency improvement in batch handling and reduced paint wastage

Smart Bin Automation – Vehicle Assembly

• Used Mitsubishi FX3U PLC to control pneumatic bin actuators
• Bins auto-opened/closed based on model-specific parameters fetched from MES
• Operator interaction is enabled through Mitsubishi GOT HMI with secure login roles

Vision-Guided Servo System for In-Line Vehicle Inspection

• Developed an advanced servo-based arm 1 DOF for 3 sets (top, left, right)
• Integrated with high-speed vision cameras to inspect specific parts of moving vehicles in the assembly shop
• Mitsubishi FX PLC with servo amplifier handled real-time positional adjustments
• Logic designed to sync with conveyor encoder pulse, allowing dynamic inspection zone targeting and adaptable to variable conveyor speed

Supervisory Control and Data Acquisition (SCADA) plays a central role in industrial automation by providing a real-time graphical interface for monitoring, controlling, and analyzing the plant environment. Our team has worked extensively with Wonderware AVEVA InTouch, Mitsubishi GOT HMI, and other SCADA platforms.

We specialize in

• Seamless integration with PLC, MES, and DB layers
• Live dashboards for operational visibility
• Multi-user role-based access control
• Real-time data logging, alarm handling, and report generation

Our SCADA solutions are designed for intuitive UI/UX, high refresh rates, and long-term maintainability with minimal overhead.

Project Implementation

Vehicle Tracking

A SCADA-driven system for real-time vehicle identification and location tracking across shop floors.

Technologies used: AVEVA InTouch SCADA, OPC-UA to PLC, MSSQL, REST API

Features:

• Dashboard view showing live vehicle movement across the paint shop, assembly, and inspection zones
• Integrated barcode/QR scanner feed to identify the vehicle by production identification number
• Historical playback of the movement path for audit

Live Vehicle Specification Display (Paint + Assembly Shop)

Customized SCADA screens to display real-time vehicle specifications at each assembly and painting station.

Technologies used: Mitsubishi GOT2000, MES link, PLC tags, DB bridge

Features:

• Auto-sync from MES/PLC to HMI screen for model-specific operations
• Visual guides for operators based on variant or trim
• Role-based lock/unlock of sensitive data (Admin, Operator, QA)
• Logging of cycle time and operator response for productivity analysis

Outcome:

• Enhanced production traceability and operator guidance
• Reduced downtime and manual coordination across departments
• Improved data accuracy for QA and reporting

Embedded systems are at the heart of smart automation, enabling real-time sensing, control, and actuation in industrial environments. We have extensive hands-on experience with custom hardware development, integration of smart sensors, and microcontroller-based control systems tailored for manufacturing and assembly automation.

Hardware platforms

• PIC microcontrollers, Raspberry Pi, Zigbee modules
• Custom-developed PCBs with optimized power, I/O, and communication interfaces
• Protocol converters and serial/Ethernet bridge modules

Sensors and Devices

• Magnetic sensors, load cells, laser safety scanners, and safety light curtains
• Ionization sensors for ESD-sensitive zones
• Pneumatic actuators integrated with embedded safety and control logic

We engineer reliable, ruggedized embedded solutions that interface with PLCs, robots, and SCADA/HMI systems through Modbus, RS232/RS485, CAN, and GPIO.

Project Implementation

Smart Door Automation for Logistics

• Embedded controller-based door opening and closing system for transport trolleys between logistics and assembly zones
• Pneumatic actuation with position feedback and fail-safe logic
• Integrated with PLC for interlocking with shop-floor workflows

Die Change Safety System in Body Shop

• Laser Sentinel Sensors interfaced via digital IO to the PLC to ensure a human-free zone during simultaneous die change
• Multiple safety zones are defined with area switch capability and interlocked with fail-safe logic

Robotic Workstation Safety

• Line curtains and load cell sensing to prevent robot motion during unauthorized human entry
• Deployed in welding and material handling cells

Wireless Acknowledgment via Zigbee

• Lightweight Zigbee mesh network for real-time work completion acknowledgment from operators

Magnetic Bearing Ball Presence Check

• Non-contact magnetic sensors for verifying the presence of bearing balls in housings
• Real-time pass/fail feedback to the visual dashboard and PLC

Ionization Dust Control System

• Custom controller for ionization air nozzles to remove electrostatic dust before painting
• Dynamic pressure control based on vehicle contour feedback from the vision system

Vehicle Battery Voltage Testing (Cobot Mounted)

• Embedded system on robot arm to check vehicle battery voltage before assembly
• Test results transmitted and logged in the central database

Outcome

• Enhanced operator safety and machine coordination
• Real-time quality checks at edge-level before reaching critical stations
• Reduced manual checks and enabled predictive safety control

Industrial IoT (IIoT) plays a pivotal role in enabling data-driven manufacturing, connecting physical devices such as sensors, controllers, and robots to digital platforms. Our solutions are designed to facilitate seamless connectivity, data acquisition, storage, and visualization across factory floors.

We have experience in building IIoT ecosystems that leverage:

• Microsoft SharePoint and OneDrive for cloud-based file/data storage
• Real-time image and inspection result uploading with model ID and timestamp tagging
• Secure data transmission using MQTT/HTTP/FTP protocols
• Edge-to-cloud connectivity with embedded gateways and lightweight client agents

These implementations empower clients to achieve traceability, reduce downtime, and enhance operational transparency.

Project Implementation

Cloud-Based Inspection Data Upload

• Inspection images and result data (PASS/FAIL, defect type) are automatically uploaded to Microsoft SharePoint
• Files organized by Model ID and Timestamp
• Used for quality audits, remote reviews, and historical traceability