UDMTEK: Revolutionizing PLC Logic Visualization for Advanced Manufacturers

Every plant has PLCs full of hidden insights. UDMTEK is the first company that can read them all and put them in front of engineers in a way that makes sense. Engineers get instant visibility into machine logic, and plant managers finally see the true causes behind downtime for better OEE. The most advanced manufacturers in the world are already doing it!

Continuing my journey through “Introduction to Industrial Automation” by George Nikolakopoulos! 🔗 From connecting PLCs across entire factories (Chapter 8) … to precisely controlling continuous processes (Chapter 9). 🚀 Continuing the Series: Chapter 9 – PID Control in the Industry We know how to turn things ON and OFF—but how do modern factories maintain perfect stability in continuous variables like temperature, pressure, flow, or motor speed? 🌡️⚡ Chapter 9 of "Introduction to Industrial Automation" explores the PID Controller—the proven feedback algorithm that has been the backbone of industrial control for over 70 years. Here’s how PID works: 🔹 Proportional (P): Reacts to the present error. 🔹 Integral (I): Accounts for the accumulated past error, eliminating drift. 🔹 Derivative (D): Anticipates the future by reacting to the error’s rate of change, reducing overshoot. By blending these three terms, a PID controller delivers fast, stable, and accurate control for almost any industrial process. The chapter also explores: ✅ Tuning Methods – from mathematical modeling to the classic Ziegler–Nichols method and hands-on trial-and-error adjustments. ✅ Implementation in PLCs – as a software Function Block (FB) for most processes or via a dedicated PID hardware module for high-speed, mission-critical control. ✅ Auto-tuning features – enabling PLCs to intelligently optimize PID parameters. 👉 Chapter 9 reveals how PID turns industrial automation from simple ON/OFF logic into continuous, intelligent control—the key to efficiency, safety, and product quality in today’s factories. #PIDcontrol #ProcessControl #IndustrialAutomation #ControlSystems #Engineering #Automation #PLC #FeedbackControl

Every controls engineer knows the feeling. A machine goes down, the PLC is running, but the logic inside is a black box. You can’t see why it failed - only flashing I/O lights and guesses. For decades, that’s been the structural flaw in automation: once deployed, PLC programs become invisible. No cross-vendor visibility, no way to replay logic, no way to see the root cause without hours of trial and error. That’s why we built UDMTEK. We developed the world’s first engine that translates and interprets PLC logic across Siemens, Rockwell, Mitsubishi, and more - turning the “black box” into a transparent system. Now you can: Trace faults to their real root cause Replay signals and logic step-by-step Let AI detect anomalies before they stop production This isn’t just another dashboard. It’s solving a structural blind spot in the industry. When PLCs are no longer opaque, predictive maintenance, faster commissioning, and real digital transformation become possible.

🚀 I recently built a Sorting Automation System using Node-RED and Factory I/O. 🟢 In this project: Sensors detect products on the conveyor. Node-RED processes the signals and controls the actuators. Products are automatically sorted into the correct path. A dashboard was created for monitoring counts and manual control. ⚡ I know that in real industrial applications, PLC controllers are more reliable and faster for handling signals compared to Node-RED, especially when it comes to processing speed and accuracy. But using Node-RED here was a great way to simulate and learn the logic of automation systems. 🏭 This type of system is widely applied in packaging factories, warehouses, and production lines to improve efficiency and reduce errors. It was an amazing experience combining simulation and control logic to bring an industrial automation process to life! #NodeRED #FactoryIO #IndustrialAutomation #PLC #SmartFactory #IIoT

The future of standardization in the context of industrial automation and control is leaning towards application-solving improvements. Here's a breakdown of the key points: In-built Libraries & Firmware Integration: Leading companies are focusing on embedding more libraries directly into the firmware. An example given is Rockwell's latest firmware, where features that once needed additional downloads (like Plant PAX) are now integrated right out of the box. Shift in Conversation: The emphasis will transition from "building from scratch" to "leveraging what's already available." The idea is that many challenges have been encountered and solved before. By building on these solutions, companies can save time and money and avoid reinventing the wheel. Cloud-based Programming: The future will see a significant move towards cloud-based programming environments. Tools like Ft Hub and the upcoming TIA Portal cloud edition are steps in this direction, making programming more accessible and centralized. Automated Code & UI Generation: Tools like Siemens' CSTAR will be instrumental. CSTAR, as part of Siemens' automation suite, not only auto-generates function blocks (akin to industry standards like Pack ML) but takes it a step further by also creating associated HMI screens for the WinCC Unified environment. This kind of integrated code and UI generation facilitates rapid development and ensures standardization. In essence, the future of standardization is about harnessing technology and existing solutions to deliver efficient, consistent, and cost-effective results in the world of automation. This clip was taken from Manufacturing Hub Episode 121 - https://lnkd.in/eYAe5s6c With Special Guest - Bobby Cole! #manufacturing #automation #industry40 #digitaltransformation

Box Sorting Automation – Factory I/O & Siemens TIA Portal ·  Designed and implemented a PLC-based box sorting system using Siemens S7-1200  In Factory I/O. ·  Integrated light array sensors for height-based sorting and retro-reflective sensors for object detection. ·  Used negative triggering (N_TRIG) logic and delayed entry conveyor control to achieve precise and reliable sorting. ·  Applied closed contact logic to maintain continuous supply flow during detection and sorting operations. #PLCProgramming #TIAportal #IndustrialAutomation #AutomationEngineering #ControlSystems #PLCtips #Siemens

Mechatronic solutions for machine building bring efficiency and flexibility to motion control with standardised applications for SIMATIC and SINAMICS. They help engineers: ⚙️ Balance loads ⚙️ Suppress vibrations ⚙️ Optimise drives With open, industry-proven modules, you can adapt solutions to your plant while reducing engineering time and complexity. 🔗 Discover practical application examples from our partner Siemens Industry:👉https://ow.ly/T3Mh50WLUFX Discuss further with our dedicated Mechatronics experts: Jason van der Merwe / Joshua Swain Doug Benton George Mackey Andy Dyer Damian Paton Sarah Black-Smith Adam Anders-Holmes Ian Connor Mark Deakin Stuart Woodall Darren O'Donnell Steve Roberts #Automation #drivetechnology #automationtechnology #automationsystems #plc #S71500 #simulation #vibration #machinedynamics

In today’s smart factories, safety and communication are non-negotiable. That’s why Schneider Electric’s Altivar Drives are built to integrate effortlessly with PROFINET and PROFIsafe, enabling high-performance automation with uncompromised safety. PROFINET Integration: • Real-time Ethernet communication for fast, deterministic control • Easy configuration with GSDML files and SoMove software PROFIsafe Compatibility: • Safety Functions for PROFIsafe (VW3A3807) Over PROFINET (VW3A3647) - Safe stop functions in accordance with EN 61800-5-2 👉 STO (Safe Torque Off) - Safe Monitoring functions in accordance with EN 61800-5-2 👉 SLS (Safe Limited Speed) - Safe Stop Functions in accordance with EN61800-5-2 👉 SS1 (Safe Stop 1) - Safety Function Not Defined in IEC 61800-5-2 👉 SMS (Safe Monitoring Speed) Why It Matters: • Reduced wiring and engineering time • Enhanced diagnostics and predictive maintenance • Improved machine uptime and operator safety Whether you're deploying Altivar Process, Altivar Machine, or Altistart Soft Starters, Schneider Electric ensures your systems are connected, protected, and future-ready. #SchneiderElectric #Altivar #PROFINET #PROFIsafe #IndustrialAutomation #SmartManufacturing #FunctionalSafety #Drives #SoftStarters #TIA #SoMove #ConnectedIndustry

🚀Automated Sorting System During my training, I built a PLC-based automated sorting system using Factory I/O integrated with Siemens SIMATIC Manger. 🔹 Problem: In manufacturing lines, cartons of different sizes need to be sorted and directed efficiently without collision. 🔹 Solution: I designed PLC logic to synchronize 4 conveyors and a turning table. The system uses sensors to detect carton sizes and direct them to the correct path, ensuring the turning table always returns to its original position before the next cycle. 🔹 Result: The simulation successfully demonstrates a real-world industrial automation process, improving efficiency and safety in material handling. 🛠 Tools & Skills: Siemens PLC, Factory I/O, Ladder Logic, Sensors, Industrial Automation code link: https://lnkd.in/dJCy38-g #PLC #FactoryIO #Automation #Mechatronics #IndustrialAutomation

Thrilled to begin exploring “Introduction to Industrial Automation” by George Nikolakopoulos! Chapter 1 sets the stage with the fundamentals of industrial control systems, highlighting how modern manufacturing blends logic, machines, and human interaction to achieve precision and efficiency. 🔑 Key Takeaways from Chapter 1: Automation vs. Process Control: Automation is about ON/OFF sequencing of devices (motors, actuators, sensors), while process control focuses on continuous adjustment of variables like temperature or liquid level. Core Components of an Industrial System: ⚙️ Motors & Actuators → the “muscles” of automation 🎛️ Handling Devices → push buttons & switches for operator input 🔔 Indicators → lights & alarms to communicate machine status 📡 Sensors → digital & analog devices that sense the environment Circuits in Automation: 🔌 Power Circuits – deliver energy to motors/devices 🧩 Automation Circuits – define the control logic 📑 Wiring Diagrams – the full physical layout for installation Modern Automation Tools: PLCs (robust, long-lasting), PACs (flexible + powerful), SCADA/DCS (centralized monitoring), and CIM models integrating field, control, and info levels. At its heart, automation improves efficiency, quality, cost, and sustainability—all crucial for today’s competitive industries. 💡 For me, the most fascinating part is how simple ON/OFF logic scales up to complex automated plants that run 24/7 with minimal human intervention. 👉 What about you? Which concept in industrial automation do you find most intriguing—PLC programming, SCADA systems, or the logic of control circuits? #IndustrialAutomation #PLC #Engineering #Automation #SCADA #Industry40 #ProcessControl #Manufacturing