DMC worked closely with the client to implement their existing machine control logic on a Beckhoff IPC. To maintain long-term flexibility, the client developed platform-agnostic control code in MATLAB, allowing them to transition to other automation platforms in the future if needed. This code was compiled into PLCopen XML files and imported into the Beckhoff XAE environment.
DMC developed the PLC logic required to interface with the customer’s control code, including handling physical inputs and outputs and communicating with higher-level building automation systems. This work included standing IO handling such as debouncing digital signals and scaling analog signals, as well as implementing Modbus/RTU communication with fan controllers. The PLC also routed commands from the customer’s custom control logic to the appropriate physical outputs.
To support integration with end-customer systems, DMC implemented multiple fieldbus options, including Modbus/RTU, Modbus TCP/IP, Profinet, BACnet IP, and BACnet MS/TP. Fieldbus parameters can be configured directly through the HMI, eliminating the need to modify the PLC program.
DMC also developed HMIs that provide clear visibility into cooler status and system operation. These HMIs allow end customers to quickly adjust fieldbus parameters without accessing the Beckhoff programming environment. Historical data and alarms are logged to internal memory, with the option for end users to export this data to an external storage device for analysis or recordkeeping.
Finally, DMC collaborated with the client to design a deployment process for new machines that does not require specialized programming software. The solution combines the Beckhoff Service Tool with custom IPC code to apply system settings. Users can import a configuration file that automatically adapts the PLC program to the appropriate hardware and software configuration, enabling fast and consistent deployment across the production facility.
Learn more about DMC’s Beckhoff programming expertise and contact us for your next project.