Integrating push buttons into SCADA

The project involved deploying and commissioning a control system for a piece of process equipment. It consisted of fitting VIPA I/O modules with digital inputs and outputs, which link the sensors and the actuators.

Push-button panels with LED indicators were integrated into the system for simple, safe operation: they indicate whether the local store for a production line is occupied. The operator switches manually between an empty and a full store, which informs the operators responsible for logistics and the warehouse.

The software part involved programming the control logic in TIA Portal V16, where we focused on fixing and extending the function blocks of the existing program. The next, equally important step was loading the program into the PLC and testing it under operating conditions.

Finally, after testing the program’s functionality, we also prepared the project documentation for the client and drew up the as-built state of the switchboard in which the I/O modules were fitted.

The implementation consisted of several technical and software steps that ensured the control system worked fully. In the first phase, I/O modules with digital inputs and outputs were fitted in the switchboard, creating the interface between the process sensors and the equipment’s actuators. The hardware integration also included connecting push-button panels with LED indicators, which allow manual control and a visual indication of the local store’s status. This made operation simple for production and logistics operators and created a clear communication link between the shop floor and the control system.

The software part was carried out in TIA Portal V16, where the existing control logic was modified and extended. New function blocks were added to interpret the signals from the panels correctly and process them in the control logic. After the changes, the program was loaded into the PLC and debugged and tested under real operating conditions, verifying the system’s functionality, stability and reliability.

The final stage of the implementation was the project documentation, which records the actual wiring in the switchboard, including the fitted I/O modules. This documentation serves not only as a technical basis for further development of the system but also as reference material for future service and maintenance work.

A working control system integrated into the production process.

Simple, safe operation using push-button panels with LED indicators.

Control logic modified and extended in TIA Portal V16 to meet operating requirements.

System functionality verified under real operating conditions.

Project documentation handed over, reflecting the as-built wiring of the switchboard.