Allen-Bradley PLC Programming

DMC provides expert programming services for Rockwell Automation products, including Allen-Bradley PLCs, HMIs, motion controllers, independent cart technology (ICT), and VFDs. With extensive experience across multiple industries, our team specializes in designing, developing, and optimizing automation solutions that maximize efficiency and reliability.

We have successfully implemented hundreds of Allen-Bradley and Rockwell Automation systems, from manufacturing and process control to motion and drive systems. Whether you need new system development, upgrades, or troubleshooting support, DMC delivers tailored solutions to keep your operations running smoothly.

Allen-Bradley PLC Programming Services

Allen-Bradley ControlLogix 5580 ControllerOur extensive Allen Bradley PLC programming experience includes implementing robust, high-performance systems utilizing the ControlLogix series and more cost-focused solutions using CompactLogix and MicroLogix controllers. We also program safe systems using Allen-Bradley's safety PLCs, including GuardLogix PLC control systems and SmartGuard safety controllers. Additionally, we offer upgrade and modification services for legacy systems utilizing the PLC-5 and SLC 500.

DMC excels at integrating the Rockwell platform with systems of any provenance. We can integrate with existing brown-field systems, develop new systems designed to integrate with future planned equipment, and develop add-on instructions (AOI) for OEM hardware manufacturers to distribute to end clients. We are proficient with many communication protocols including EtherNet/IP, Modbus, DF1, ControlNet, DH-485, DeviceNet, and Ethernet.

Rockwell Automation Gold System Integrator

DMC is a Rockwell Automation Gold System Integrator. This recognizes our knowledge and experience in design, implementation, project management, and maintenance of Rockwell Automation industrial control systems. DMC has demonstrated expertise with Rockwell Automation technologies and platforms such as ControlLogix, CompactLogix, FactoryTalk View, MagneMotion, Kinetix Motion Controllers, PowerFlex VFD Drives, PanelView, and more.

Our integration services go beyond PLCs, including motion control (Kinetix Servos and PowerFlex VFDs), Independent Cart Technology (ICT, MagneMotion, and iTraK), and HMI, SCADA, and MES development using PanelVIEW interfaces including:

  • FactoryTalk Optix
  • FactoryTalk View SE
  • FactoryTalk View ME
  • RSView
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FAQs

What are programmable logic controllers and why are they important in industrial automation systems?

Programmable Logic Controllers (PLCs) are specialized industrial computers used to automate manufacturing processes, machinery, and robotic systems. They are usually embedded devices that run only the program downloaded to them rather than being a general purpose computer. This allows the PLC to operate in a deterministic manner that provides the robustness, reliability, and predictability needed for industrial automation. This fundamental characteristic also allows for features such as live editing while a system is running which enables problem resolution and system modification without stopping a machine that is running production. Modern PLCs have built on this core robust architecture by adding in enhanced communication capabilities for interoperability and data collection as well as integrated machine safety to allow a greater level of flexibility in providing safety rated systems. In summary, their flexibility and scalability make them a cornerstone of modern industrial automation across industries like manufacturing, energy, and transportation.

How can you test and debug a PLC program to ensure it functions properly?

Studio 5000 is the software used to program Allen-Bradley PLCs and it is also the program used in commissioning, debug, and diagnostics. Program execution can be monitored against the actively running PLC and internal variables and I/O points can be viewed both in the PLC program code itself and in dedicated watch tables. The graphical nature of ladder programming provides a visual and invaluable ability to understand how a program is operating at a glance and is uniquely suited to diagnosing issues with systems like malfunctioning I/O.

How can I use a PLC to monitor my system performance and make improvements to operation and efficiency?

The fundamental design of a PLC that allows it to be highly capable as a platform for machine control platform also gives it the capability to optimize operations. The built-in online diagnostics provide an efficient method for diagnosing and rectifying machine problems. Modern SCADA systems and Industrial IoT (IIoT) edge platforms enables collection and analysis of production data and generation of metrics like Operational Equipment Efficiency (OEE), timing analyses, and fault logging to understand the state of your system and the potential target areas for improvement.

What steps should be followed to use PLCs for industrial automation effectively?

A well designed system is key to getting the most out of your PLC system. Start by developing system requirements, determining the number and types of I/O, and the communication to external devices. This will help chose the right PLC with the correct amount of processing speed and memory for program storage for the application. The system should then be programmed with a well-architected program following standards, such as PackML, that are appropriate for the application. The PLC, I/O, and related devices should be installed in an electrical panel designed and built to quality standards like UL 508A even if certification is not required. Electronic and physical copies of electrical drawings should accompany the system to allow for field commissioning and future diagnostics. The system should undergo a factory acceptance test before delivery and a site acceptance test after install and commissioning to ensure that all requirements are met on the delivered system. Finally, the PLC can be used to identify the need for additional maintenance through predictive maintenance programming, maintenance counters, or fault alarms that indicate the need for service.

Optimize Your Automation with Expert Allen-Bradley PLC Programming

Contact us today to discuss your project and discover how DMC can help
you achieve smarter, more reliable automation!