Controls Engineering Services for Industrial Automation
The Complete
Automation Stack.
Controls engineering services for the complete automation stack. PLCs and robots get the attention, but it's the drives, vision systems, conveyors, and safety devices that make a production line actually WORK. We integrate it all—from individual VFD commissioning to complete line automation.
Capabilities
Controls Systems We Integrate
From 1HP VFDs to enterprise-level safety architectures—we handle the full controls stack.
VFD Commissioning & Drives
Variable frequency drives, DC drives, soft starters. 1HP to 500HP.
Servo Drive Integration
Precision motion control for indexing, positioning, synchronized axes.
Vision System Integration
Machine vision for inspection, guidance, identification.
Industrial Safety Systems
Safety PLCs, light curtains, E-stops, Cat 3/4 functions.
Conveyor System Controls
Belt, roller, chain, power & free controls.
Industrial Network Integration
EtherNet/IP, PROFINET, CC-Link, Modbus, EtherCAT.
Platforms
Controls Engineering Platforms
VFD Commissioning & Drives
Capabilities
- Parameter setup & auto-tune
- PLC communication setup
- Multi-drive coordination
- Energy optimization
Platforms
Services
Controls Integration Services
New Build Controls Integration
Complete controls from concept to production. Panel design, programming, wiring, commissioning, and startup support.
Deliverables: Control panel, PLC program, HMI, documentation
Controls Retrofit & Modernization
Update older machines with modern automation. PLC migrations, drive replacements, network upgrades—without rebuilding the entire machine.
Deliverables: Upgraded system, migration documentation
Controls Troubleshooting & Support
When your team hits a wall, we step in. Remote diagnostics, on-site troubleshooting, root cause analysis, and permanent fixes.
Deliverables: Root cause report, corrective actions
Controls Integration Case Study
Complete Line Integration for Beverage Packaging
Multi-vendor packaging line
Challenge
8 OEM machines from 6 different vendors. Target: 1,200 BPM line speed. 12-week timeline for full integration and commissioning.
Solution
- ControlLogix master PLC with line-wide coordination
- EtherNet/IP backbone connecting all 8 machines
- Cognex vision inspection at 3 critical stations
- GuardLogix safety system to PLd compliance
Results
FAQ
Controls Engineering FAQ
Everything from single VFD commissioning to complete production line integration. We work on new builds, retrofits, and troubleshooting across all major automation platforms.
Yes. We provide full electrical design, panel layout, BOM generation, and can manage panel fabrication through our partner shops. All designs meet UL 508A and NFPA 79 standards.
Absolutely. We specialize in integrating modern controls with existing legacy equipment. PLC-5 to ControlLogix migrations, S5 to S7 conversions—we've done them all.
We follow ISO 13849 and IEC 62061 for safety system design. This includes risk assessment, safety circuit design, validation testing, and compliance documentation.
Simple VFD commissioning can be done in a day. Full line integration typically takes 8–16 weeks depending on scope. We always provide a detailed timeline during the proposal phase.
Yes. Every project includes operator and maintenance training. We provide hands-on training at your facility plus documentation your team can reference.
