Automation solutions

Industrial automation encompasses the technical planning, control, and networking of machines, systems, and production processes. This includes, for example, PLCs, sensors, actuators, robotics, visualization, and safety functions. Leadec supports automation projects from conception and project planning through hardware planning, software development, control cabinet construction, and electrical installation all the way to commissioning. Both individual process steps and entire production lines can be automated. It is crucial to evaluate the benefits, process stability, variations, interfaces, and future maintainability in advance.

PLC programming provides the logical control for many automated machines and systems. This includes sequence control, interlocks, error handling, communication with sensors and actuators, and integration with HMI or SCADA systems. Leadec programs systems from various manufacturers, including Siemens, Rockwell, Beckhoff, and other platforms. Good PLC programming should be structured, documented, and maintainable. Standards and clear interfaces are particularly important for complex systems to ensure that future changes and troubleshooting remain manageable.

The automation of industrial plants begins with a process and requirements analysis. Next, the automation concept, control technology, sensors, actuators, safety functions, and interfaces are planned. This is followed by software programming, electrical design, control panel construction (if necessary), and testing. Leadec can also prepare a virtual commissioning using a digital twin before the actual plant is brought online. On-site, control systems and components are connected, tested, and optimized. Structured commissioning support helps systematically eliminate errors and achieve the target performance.

A retrofit can be a sensible option when a system that is still mechanically serviceable is limited by outdated control systems, a lack of replacement parts, limited data availability, or new product requirements. Instead of replacing the entire machine, the control system, sensors, drives, safety functions, and communication systems can be modernized. Leadec offers retrofit and modernization services for existing systems. Before proceeding, the remaining service life, production risk, spare parts availability, and desired enhancements should be evaluated to ensure that the retrofit is designed to be economically and technically viable.

When integrating robots, the mechanical design, grippers, sensors, safety concept, PLC communication, and production process must all be coordinated. Leadec programs robots from various manufacturers and supports both new installations and modifications to existing systems. Before implementation, specialized simulation tools can help optimize motion sequences and check for potential collision areas. It is also important to ensure a smooth handover to operators and maintenance personnel. For this reason, documentation, a spare parts strategy, and training should be planned as part of the automation project from the outset.

In virtual commissioning, the behavior of a plant is digitally simulated before actual production begins. To do this, Leadec creates a digital twin and connects it to the intended control software. This allows processes, signals, and error scenarios to be tested early on, before the PLC goes live on the actual plant. While this does not eliminate every risk, it can help identify software errors and integration issues sooner. Especially when ramp-up times are tight, this can save valuable time on-site.

Modern automation systems are increasingly exchanging data with production IT, MES, ERP, or cloud applications. This results in more interfaces between OT and IT. During the design phase, Leadec takes into account both the planning of these interfaces and an IT security strategy. Key factors include network segmentation, defined access rights, secure remote maintenance, and clear lines of responsibility. Security measures must take into account the high availability requirements of production. Cybersecurity should therefore be an integral part of the architecture from the outset, rather than an afterthought.

Automation projects must take into account technical safety, functional safety, and traceable documentation. Leadec lists safety analyses, SIL or PL verification, and CE-compliant implementation, among other things, as components of its range of services. The specific requirements depend on the machine, the system, and the role in the project. A clear risk assessment, coordinated protective functions, and complete documentation for operation and maintenance are essential. Safety requirements should be considered as early as the design phase, because making adjustments later is often time-consuming.

Manufacturer-independent automation means that solutions are not inherently limited to a single control, sensor, or robotics platform. Leadec works with its own development tools and systems from various manufacturers and programs platforms such as Siemens, Rockwell, Beckhoff, Schneider Electric, Yokogawa, and others. This can be helpful for heterogeneous existing plants or corporate standards. Nevertheless, the choice of system should not be made arbitrarily: availability, existing expertise, spare parts, interfaces, and long-term maintainability must be suitable for the respective plant.

Once commissioning is complete, the long-term operation of the automation system begins. Relevant services include software support, maintenance, spare parts supply, troubleshooting support, and adaptation to new products or processes. Leadec offers after-sales services, a remote maintenance concept, and regular maintenance. It makes sense to have a service agreement with clear response times, responsibilities, and access rules. In addition, software versions, backups, and changes should be documented so that the system can continue to be reliably supported even years after the project is completed.