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Industrial Automation & PLC Programming

Efficient Automation for Industry, Machinery, and Plant Engineering

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Ihr vertrauensvoller Partner in Sachen Maschinen- und Anlagensteuerung durch Einsatz von SPS Steuerungen.

Efficient CPU Programming for Industrial Automation

With our extensive experience and deep expertise, we provide tailored solutions for controlling your machines and systems. Our specialists support you in the planning, implementation, and optimization of automation processes to enhance the efficiency and productivity of your operations.

A solid understanding of PLC programming fundamentals is essential for selecting the right devices and components to ensure optimal control of machines and systems.

What We Offer

  • We develop customized control and regulation programs using IEC 61131-3 and UL508-compliant programming languages.
  • Our modular PLC solutions, designed with specialized modules for different tasks, ensure reliability, scalability, and easy maintenance for smooth plant operations.
  • We work with the most widely used PLC systems, seamlessly integrating with EPLAN to establish a direct interface for streamlined electrical design.
  • From wiring to commissioning, we oversee the entire process and support you through acceptance testing.
  • Our expertise in electrical and mechanical design, combined with programming know-how, enables efficient interdisciplinary collaboration between departments.

By partnering with us, you ensure seamless automation, optimized performance, and maximum system reliability.

Our Services in CPU Programming & Industrial Automation

We offer comprehensive services backed by highly skilled PLC programmers, ensuring compliance with ISO 13849, IEC 61508, and IEC 62061 standards. Our expertise covers:

  • Development of Functional Analyses – Ensuring precise and structured control logic
  • Component & Software Selection Support – Assisting in choosing the right control components and programming languages.
  • PLC & HMI Programming – Designing user-friendly and efficient automation interfaces.
  • Modernization of Legacy Systems – Upgrading outdated control systems for improved performance and reliability.
  • Industrial Maintenance & Program Optimization – Ensuring smooth operation and adapting software as needed.
  • DCS Programming Development – Custom solutions for distributed control systems.
  • FAT/SAT Validation & Compliance Testing – Ensuring systems meet functional and safety requirements.
  • Commissioning & Acceptance Testing – End-to-end support for seamless system integration.
  • Comprehensive Documentation – Detailed architecture and output mapping for transparency.
  • Training & Workshops for Maintenance Teams – Knowledge transfer to keep your staff up to date.
 

With our structured approach and interdisciplinary expertise, we ensure maximum efficiency, reliability, and future-proof automation solutions.

 

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MIS 1 - Fore Group

Our Expertise in PLC & Industrial Automation

🔹 Consultation on PLC Selection – Tailored recommendations based on application requirements.
🔹 PLC Programming Across Various Manufacturers – Flexible solutions for diverse automation needs.
🔹 Automation Systems for Production & Processing – Optimized control for industrial workflows.
🔹 HMI Visualization – Intuitive interfaces for seamless interaction.
🔹 Control Systems for Machines & Plants – Reliable and precise automation solutions.
🔹 Productivity Optimization for Existing Systems – Enhancing efficiency and performance.
🔹 Development of SCADA Monitoring Systems – Real-time supervision and control.
🔹 Alarm, Recipe & Trend Management – Advanced monitoring and automation capabilities.
🔹 Data Archiving & Optimization – Secure storage and efficient data handling.
🔹 Audit-Trail & 21 CFR Part 11 Compliance – Ensuring traceability and regulatory adherence.
🔹 Database Configuration & Integration – Structured data management for automation.
🔹 Interfaces to ERP Systems – Seamless communication between automation and enterprise systems.
🔹 Custom HMI Development – Tailored user interfaces for enhanced usability.
🔹 Configurable & Customizable Reporting – Comprehensive insights at a glance.
🔹 Remote Access & Mobility Solutions – Control your automation systems anytime, anywhere.

We deliver tailored automation solutions that drive efficiency, compliance, and innovation.

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Our Experts in PLC Programming

Our team consists of highly skilled professionals in PLC programming, with extensive expertise in control, regulation, and automation. To ensure that our specialists stay up-to-date with the latest technological advancements, we offer training and courses in industrial automation.

What is PLC Programming?

PLC (Programmable Logic Controller) programming is a key technology in industrial automation, allowing precise computer-controlled instructions for specialized machines. These PLCs are widely used in factories and industrial environments to perform specific tasks efficiently and reliably. By developing PLC programs, machines can execute complex operations, optimize workflows, and improve overall efficiency—resulting in higher productivity and streamlined production processes.

The Role of a PLC Programmer

A PLC programmer is a highly qualified expert responsible for designing, developing, and implementing automation solutions for industrial systems. Their primary tasks include:

  • Programming and optimizingcontrol systems for electrical machines and production lines
  • Defining and implementingfunctional machine sequences
  • Developing advanced automation strategiesto enhance production efficiency
  • Collaborating closelywith engineers and technicians to ensure seamless integration
  • Testing, debugging, and optimizing PLC softwareto ensure reliability

By combining deep technical knowledge with practical experience, our experts ensure that industrial processes run smoothly, efficiently, and in compliance with industry standards.

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Siemens Sps e1736601216980 - Fore Group

Why Siemens?:

  1. Reliability and Quality
    Siemens PLC systems, such as the SIMATIC S7 series, are globally recognized for their high reliability and quality. They have proven their performance in numerous industrial applications and offer a long service life.
  2. Reliability and Quality
    Siemens PLC systems, such as the SIMATIC S7 series, are globally recognized for their high reliability and quality. They have proven their performance in numerous industrial applications and offer a long service life.
  3. Innovative Technologies
    Siemens integrates cutting-edge technologies such as the Industrial Internet of Things (IIoT) and provides comprehensive automation solutions. This ensures efficient and future-proof production.
  4. Global Support and Comprehensive Documentation
    Siemens offers extensive global support along with a wide range of training materials and documentation. This facilitates system implementation and maintenance while ensuring users worldwide receive the necessary assistance.
Beckoff SPS e1736541374780 - Fore Group

Why Beckoff?:

  1. Precise Motion Control

    In robotics and CNC machines, where extremely precise and fast motion control is required, Beckhoff offers advantages through its powerful EtherCAT communication protocols and high-speed cycle times.

  2. Modular and Scalable Systems

    Beckhoff provides a highly modular and scalable architecture, allowing flexible system adaptation to various requirements. This is particularly beneficial in production line automation, where frequent adjustments and expansions are needed.

  3. Open and Flexible Programming

    Beckhoff utilizes the TwinCAT system, based on standard PC technology, offering an open programming environment. This is advantageous when integrating custom or specialized software solutions.

  4. Cost and Performance

    In some cases, Beckhoff provides a cost-effective solution, especially when high performance and flexibility are required. This is particularly relevant in industries such as packaging and electronics manufacturing.

     

Alen Bradley SPS - Fore Group

Why Rockwell?

  1. User-Friendly and Intuitive Programming

    Rockwell Automation controllers are known for their user-friendly software, particularly RSLogix 5000 (now Studio 5000). This software provides an intuitive programming environment, making it easy to learn, especially for users familiar with ladder logic.

  2. Strong Presence in North America

    Rockwell Automation has a strong market presence in North America and is often the preferred choice for industrial automation solutions in the region. This can be especially beneficial for businesses operating in or expanding into this market.

  3. Integrated Safety Solutions

    Rockwell offers comprehensive, integrated safety solutions that seamlessly connect with its control systems. These include both hardware and software solutions designed to enhance machine and plant safety.

  4. Extensive Support and Training

    Rockwell Automation provides extensive support and training programs to help users operate and maintain their systems efficiently. This includes both online resources and in-person training sessions.

TIA V20 - Fore Group

Siemens TIA Portal V20 – A Powerful Tool for Industrial Automation

The Siemens TIA Portal V20 offers numerous advantages, making it a powerful tool for industrial automation. Below are some of its key benefits:

  1. Enhanced Performance and Efficiency

    TIA Portal V20 significantly improves the performance and efficiency of automation processes. It supports the latest PLC models, including the S7-1200 G2 and the modular S7-1500 CPUs, providing higher computing power and improved control functions.

  2. User-Friendly Interface

    The new version features a text-based representation of graphical code, making programming more intuitive. It also enables easier integration of external tools such as GIT and Beyond Compare, improving workflow efficiency.

  3. Integrated Security Features

    TIA Portal V20 enhances security by integrating SIMATIC PLCs into a centralized user management system. This allows technicians to access devices using standard enterprise login credentials without compromising security.

  4. Cloud Capabilities and AI Integration

    With cloud connectivity and generative AI integration, TIA Portal V20 improves collaboration and efficiency. These features support automation engineers in their daily work while ensuring seamless functionality and security updates.

  5. Advanced diagnostic and maintenance functions: TIA Portal V20 provides advanced diagnostic and maintenance features that enable rapid fault detection and troubleshooting. This helps reduce downtime and increase productivity [2].
These advantages make Siemens TIA Portal V20 an attractive choice for companies looking to optimize their automation processes and future-proof their production systems.

[1]: TIA Portal Version 20: Enabling Peak Performance and Efficiency [2]: Product Information for TIA Portal V20 and Options
References
Beckhoff TwinCAT e1736539783448 - Fore Group

TwinCAT 3 from Beckhoff offers numerous advantages that make it a powerful and flexible solution for industrial automation. Below are some of the key benefits:

  1. Integration of all engineering tools: TwinCAT 3 integrates all necessary engineering tools into a single environment, namely Microsoft Visual Studio®. This enables seamless development and maintenance of automation projects [1].
  2. Free choice of programming language: TwinCAT 3 supports various programming languages such as IEC 61131-3, C/C++, and MATLAB®/Simulink®. This gives developers the flexibility to choose the language best suited to their specific requirements [1].
  3. Modularity and scalability: The modular concept of TwinCAT 3 enables a clear separation between engineering and runtime. This simplifies programming and execution and allows functional changes and extensions at any time [2].
  4. Real-time capability: TwinCAT 3 turns almost any PC-based system into a real-time control system with multiple PLC, NC, CNC, and/or robotics runtime systems. This ensures high performance and precision in control [2].
  5. Open architecture: TwinCAT 3 offers an open architecture that allows the integration of third-party components and customized retrofit solutions for existing machines and systems. This increases flexibility and protects the customer’s investment [2].
  6. Support for IoT and analytics: TwinCAT 3 integrates IoT and analytics functions that enable simplified communication and data analysis. This supports modern Industry 4.0 applications and improves efficiency and transparency in production [1].

These advantages make TwinCAT 3 an attractive choice for many industrial applications.

[1]: TwinCAT 3: The flexible software solution for PC-based control [2]: TwinCAT 3 | Automation software | Beckhoff Switzerland (German)

References
Studio5000 - Fore Group

Studio 5000 von Rockwell Automation bietet zahlreiche Vorteile, die es zu einer leistungsstarken und effizienten Lösung für die industrielle Automatisierung machen. Hier sind einige der wichtigsten Vorteile:

  1. Einheitliche Plattform: Studio 5000 bietet eine einheitliche Umgebung zum Entwerfen und Programmieren von Steuerungssystemen. Dies vereinfacht die Entwicklung und Wartung von Automatisierungsprojekten[1].

  2. Benutzerfreundliches Interface: Die Software ist speziell für Programmierer entwickelt und bietet eine intuitive Benutzeroberfläche, die komplexe Aufgaben vereinfacht und die Produktivität steigert[1].

  3. Skalierbarkeit: Studio 5000 ist für kleine bis große Automatisierungsprojekte geeignet und bietet eine hohe Skalierbarkeit, um den Anforderungen verschiedener Anwendungen gerecht zu werden[1].

  4. Schnellere Markteinführung: Durch die Optimierung der Produktivität und die Verkürzung der Inbetriebnahmezeit ermöglicht Studio 5000 eine schnellere Markteinführung von Produkten und Systemen[2].

  5. Wiederverwendbarkeit und Zusammenarbeit: Die Software unterstützt die Wiederverwendung von Code und fördert die Zusammenarbeit zwischen verschiedenen Teams, was die Effizienz und Qualität der Projekte erhöht[2].

  6. Virtuelles Design und Simulation: Studio 5000 bietet Funktionen für virtuelles Design und Simulation, die es ermöglichen, Steuerungssysteme unabhängig von der Hardware zu validieren, zu testen und zu optimieren[2].

  7. Erweiterte Diagnosefähigkeiten: Die Software bietet erweiterte Diagnosefähigkeiten, die eine schnelle Fehlererkennung und -behebung ermöglichen, was die Zuverlässigkeit und Verfügbarkeit der Systeme erhöht[3].

Diese Vorteile machen Studio 5000 zu einer attraktiven Wahl für viele industrielle Anwendungen.

[2]: Designsoftware Studio 5000 | FactoryTalk – Rockwell Automation [3]: Studio 5000 Logix Designer | FactoryTalk – Rockwell Automation [1]: Mastering Studio 5000 und RSLogix 5000 für die Automatisierung

References
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  1. Multitouch operating panels: These panels enable intuitive operation through multi-finger inputs. They often use Projected Capacitive Touch (PCT) technology, which allows precise and fast response to touch inputs.
  2. 3D gesture control: This innovative technology allows machines to be controlled using three-dimensional gestures. This can be done by swiping, tapping, and moving elements on the screen, similar to modern smartphones.
  3. Eye tracking: This technology tracks the operator’s eye movements and enables hands-free control of machines. It is particularly useful in environments where the operator needs to keep their hands free for other tasks.
  4. Voice input and output: Voice control systems allow machines to be operated using spoken commands. This can increase efficiency and safety, as the operator does not need to constantly look at the HMI.
  5. AR and VR applications: Augmented Reality (AR) and Virtual Reality (VR) provide immersive ways to visualize and interact with machines. These technologies can present complex data and processes in a clear and accessible manner.
MIS 3 - Fore Group

PROFIBUS Advantages:

Robustness and Reliability: To ensure reliable machine operation, PROFIBUS is well suited for industrial use, as it is known for its high reliability and robustness in industrial environments. It is less susceptible to electromagnetic interference and can operate stably in harsh conditions. Easy Integration: PROFIBUS enables simple integration of devices from different manufacturers. It is a widely used standard that allows seamless communication between various devices, machines, and systems. Deterministic Data Transmission: PROFIBUS provides deterministic communication, meaning data transmission is time-predictable. This is particularly important for time-critical applications in automation technology. Low Latency: PROFIBUS offers very low data transmission latency, enabling fast responses to control commands. Cost Efficiency: In many cases, implementing PROFIBUS can be more cost-effective than Ethernet-based systems, especially when existing infrastructure can be reused.

PROFINET Advantages

Real-time capability: The use of PROFINET enables real-time transmission of machine data, which is particularly important for time-critical processes in industrial automation. High flexibility: PROFINET supports various network topologies and allows flexible installation. It can be used in both small and large networks. Scalability: PROFINET is scalable and can be adapted to the requirements of different processes. It supports both simple control tasks and complex automation systems. High availability: PROFINET provides high availability and reliability, which is essential for the continuous operation of industrial plants. Integration of IT and OT: PROFINET enables seamless integration of information technology (IT) and operational technology (OT), increasing efficiency and transparency in production. Diagnostic and maintenance functions: PROFINET offers extensive diagnostic and maintenance capabilities that allow rapid fault detection and troubleshooting.

Ethernet Advantages

Higher data transmission rates: The use of Ethernet offers significantly higher data transfer rates (up to 10 Gbit/s and more) compared to PROFIBUS, which typically achieves data rates of up to 12 Mbit/s.

Flexibility and scalability: Ethernet is highly flexible and can be easily scaled to meet the requirements of growing networks. It supports various network topologies such as star, tree, and ring. Wide acceptance and availability: Ethernet is a widely used standard in many IT and industrial applications. This results in broad availability of hardware and software solutions. Integration of IT and OT: Ethernet enables seamless integration of information technology (IT) and operational technology (OT), increasing efficiency and transparency in production. Cost efficiency: Ethernet hardware and infrastructure are often more cost-effective than specialized PROFINET components, as standard components and interfaces are widely used. Universal application: Ethernet can be used in a wide range of applications, from home networks to large enterprise networks, whereas PROFINET is specifically designed for industrial automation applications. Standardization: Ethernet is based on widely adopted and standardized protocols (IEEE 802.3), which facilitates interoperability between different manufacturers and systems.

EtherCAT Advantages

EtherCAT (Ethernet for Control Automation Technology) is a specialized protocol based on Ethernet, optimized for real-time applications in industrial automation. It was developed by Beckhoff and is managed by the EtherCAT Technology Group.

EtherCAT uses a “processing-on-the-fly” method, where data packets are processed directly within the nodes as they pass through the network. This enables extremely fast and deterministic data transmission. EtherCAT does not require IP addresses for devices. The wiring order defines the devices within the network, allowing for flexible and simple installation. EtherCAT is specifically designed for industrial automation applications that require high speed and precision.
  • In summary, it can be stated:

With technological developments and advancements, control systems are becoming increasingly complex and powerful. Modern PLC systems are not only fast and precise, but are also capable of performing complex calculations and controlling a large number of inputs and outputs simultaneously.

PLC technology is therefore fundamental to automation, as it enables the transition from purely mechanical processes to digital machine control.

We are your experts in PLC programming!

What we offer:

  • Automation as a central element of communication between machines and systems
  • Wide range of applications → From controlling individual machines to networking entire production facilities
  • Comprehensive technical know-how and in-depth knowledge of PLC programming languages
  • PLC programming in various programming languages:
    • AWL (Instruction List)
    • KOP (Ladder Diagram)
    • FUP (Function Block Diagram)
    • SCL (Structured Control Language)
  • Extensive technical skills and expertise in project coordination
  • Flexibility and agility → We adapt to the specific requirements of your project
  • Visualization of data and control processes in HMI systems (Human Machine Interface)
  • Close collaboration and intensive exchange between PLC programmers, specialists, electricians, and engineers

Take the next step with us!

Submit your inquiry now!

Steps of Collaboration

Initial contact
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FAQ – Frequently Asked Questions

We work with a wide range of systems and adapt to our customers’ requirements. Most commonly, software for Siemens PLC systems is requested, followed by Beckhoff. In international projects, we have worked with Rockwell, Schneider, ABB, and Mitsubishi.
The FoRe Group takes care of the infrastructure and adapts to the customer’s requirements. We ensure that we do not work with newer software versions than those used by the customer and we also provide the program files.

The FoRe Group acts as the contractor and transfers the rights to the work performed to the client. We are also happy to support you in applying for development grants, which can be requested by the client.

It is best to clarify this in a joint discussion. During this conversation, your needs are analyzed first, and based on that, we offer you the optimal solution.

We offer hourly rates starting at €30/hour for engineering services. Depending on the scope of work and specific requirements, the rate may increase. We can also take on complete projects, including project management and communication with the end customer. In such cases, we are happy to offer a blended pricing model.

Using our engineering services offers the advantage of allowing you to respond flexibly to your staffing situation. You can make use of engineers only when you actually need them and do not have to worry about salaries or social security contributions. In addition, you have the option to deploy specialists with specific skills and qualifications for particular projects.

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