PLC Automation and Electrical
In a paint shop, surface treatment, booth, oven and conveyor do not operate independently — what the others do when one stops must be defined in advance. The automation layer establishes this coordination and makes the line behave as a single machine.
How the process works
The control architecture is generally three-layered. Field layer: sensors, motors, valves. Control layer: the PLC and safety PLC manage the field over a fieldbus. Supervisory layer: the operator panel and SCADA display the line status, store parameters and report production data.
Safety functions run in a circuit separate from normal control. The performance level required for each function — emergency stop, door interlock, area scanner — is determined by risk assessment; EN ISO 13849-1 defines the method for this calculation.
Recording process data is increasingly mandatory in customer specifications. Being able to trace which part passed at which oven temperature and with which bath parameters is an acceptance condition, particularly in automotive and aerospace.
Our scope
- Control panel design, manufacturing and field wiring
- PLC programming and operator panel (HMI) design
- Safety PLC and design of safety circuits
- SCADA, data acquisition, traceability and reporting
- Zone-based monitoring of energy consumption
- Commissioning, site testing and documentation
Technical framework
| Compliance | EN 60204-1 · EN ISO 13849-1 |
|---|---|
| Control | PLC + safety PLC |
| Supervision | Operator panel (HMI) · SCADA |
| Traceability | Process parameter recording per part |
The figures are typical operating ranges for the sector. Every line is recalculated according to part geometry, target capacity, paint system and customer specification.
Frequently overlooked points in design
- Source code and documentation: The source code of the PLC program and the electrical drawings must be part of the delivery. Otherwise every future change remains tied to a single supplier.
- Spare parts list: The make and model of critical components must be recorded during commissioning.
- Remote access: If a remote connection is planned for support, the cyber security approach must be agreed from the outset.
Related topics
Let’s arrange a preliminary technical discussion on automation and electrical infrastructure. Share your part dimensions, target capacity and paint system, and our process engineer will prepare an outline concept and budget range.