What is A&C?
The company, A&C Automationssysteme & Consulting GmbH, was founded in 1979 as Leo Stadlmayr Electrical & Control Systems. We are a technical office that operates in the field of industrial plant automation and offers its services worldwide. We are active in a range of fields with a variety of automation systems and continually expand our offer portfolio.
Services
A&C offers E/I&C services in the area of industrial plant automation, which extend from consulting and hard- and software engineering, to turnkey projects and networks, etc. ... Read more here
System and tool portfolio
Over the years, we have continually expanded our portfolio of systems and tools. You will find a related list here.
Turnkey projects
Apart from the services mentioned above, A&C also completes turnkey projects. These can involve multiple process control and server client systems for operations and data archiving, PLC-based machine controls and migrations, i.e. the exchange of existing controls ...
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Migrations
Experience shows that production machinery and processing plants frequently have longer life cycles than switchgear and control systems. New switchgear with the related automation can increase machine availability and reduce costs.
We are pleased to offer flat rate migrations for transport, filling, bagging and palletizing systems, as well as saws, sawmills and sorting machines ... Read more here
Industrial networks
For us, the topic of networks relates to the stability and safety of automation systems (operational technology - OT), on the one hand from controls to the servers and on the other, from the servers to the operating stations. Moreover, in view of the fact that an increasing number of “external” accesses to the automation network such as data logging, office use and remote maintenance have become necessary... Read more here
Software
Functional descriptions (written or verbal) serve as a basis for control applications, function plans and interlock diagrams, or existing control applications. A&C transcribes verbal, functional descriptions into written form, which are then presented to the customer or the operator for examination and approval. In the case of pure migration projects ... Read more here
Hardware
At the beginning of a project, we deal with all the most important aspects of the plant planning during personal discussions with our customers. Owing to their experience our designers are able to think in interdisciplinary terms and therefore other areas of activity are also accounted for during detailed planning ... Read more here
Consulting
A&C supports its customers during the entire duration of E/I&C, greenfield and brown field projects... Read more here
Robotics
Irrespective of whether pick and place, mounting, palletizing, stacking, part handling, packing, painting, welding or cutting are involved, robots have become a virtually indispensible part of production, logistics and laboratory work ... Read more here
Camera systems
Today, cameras constitute the "eyes" of automation. Machine vision encompasses technologies and methods that enable the image-based, automatic inspection and analysis of applications such as automatic quality control, process control and robot guidance... Read more here
A&C offers its services in both a managerial form and at a flat rate within the scope of a clearly defined project framework. We work largely in the paper, energy, plastics and coating, cement, automotive, steel, intralogistics/transport technology and wood processing industries, using standard CAE systems, process control systems (PCS) and programmable logic controllers (PLC).
Through these activities we have also acquired a great deal of experience in the fields of wastewater treatment and continuous processes in general.
Apart from the services mentioned above, A&C also completes turnkey projects. These can involve multiple process control and server client systems for operations and data archiving, PLC-based machine controls and migrations, i.e. the exchange of existing controls in the course of a follow-up project or the PLC of another manufacturer, the integration of new machine parts into an existing process control system or other customized camera- or sensor-based inspection systems.
Process control systems
A&C plans hard- and software in accordance with customer stipulations and specifications. In addition, A&C and its long-term partner companies build control, peripheral and computer cabinets. In this regard, state of the art process control systems also offer the possibility of operational level virtualization and we are pleased to present our customers with the advantages and disadvantages, as well as the differing costs of this solution, or a conventional implementation.
Following engineering, A&C prepares the appropriate environments or actual hardware for the testing of each simulation, which is then completed jointly with the customer. After the successful conclusion of such tests, commissioning can commence. We are pleased to involve our customers in the various engineering, testing and commissioning phases, in order to both save project costs and simplify any subsequent maintenance and minor adjustments to the process control system.
PLC, machine-related controls
As in the case of process control systems, A&C plans the hard- and software in accordance with customer stipulations and specifications. A&C designs the control and peripheral cabinets, which are then built by long-term partners. Integrated panels or PCs are employed as operating surfaces.
Testing and inspection equipment
A&C draws up concepts for camera- and sensor-based testing and inspection equipment in accordance with customer requirements. This equipment is either integrated into ongoing production processes (with links to existing control systems, process control systems or OPC servers), or is installed as a stand-alone solution with its own control and operating unit. The choice is always dependent upon the respective demands of the customer or the production process.
QCS, cross and machine direction regulation
Originally developed for the coating of lengths of cartonboard for beverage packaging, our PCS7-based cross and machine direction regulation is also used in paper and board machines. The A&C QCS application is programmed in SCL and to date has been employed mainly in PCS7 environments although the code can also be utilized in other PLS or SPS environments.
Experience shows that production machinery and processing plants frequently have longer life cycles than switchgear and control systems. As a rule either no, or only second-hand, spare parts are available, enlargements cannot be implemented or new functions are planned. In the plant modernization field we offer an extensive services portfolio and new switchgear with the related automation can raise machine availability and lower costs.
We are pleased to offer flat rate migrations for transport, filling, bagging and palletizing systems, as well as saws, sawmills and sorting machines.
Document revision
Migration constitutes the ideal point in time for complete documentation updates. A&C revises your available electrical documents or furnishes new switchgear and subsequent replacement.
Customization of the operating and safety concept
During the implementation of plant software, it is of importance to also reassess the dangers to the operating personnel. In addition, this offers a chance to undertake modifications and improvements to the operating concept.
New programming and enlargement
This is the key element in migration. A&C specializes in the adaptation of old systems to the state of the art and thus the removal of inherited problems, the optimization of sequences and the integration of new functions into the plant, in order, e.g. to provide maintenance personnel with easier access.
Interfaces to other systems
It is clear that existing systems must be able to coexist with new ones. For this purpose, A&C adapts and tests all interfaces.
For us, the topic of networks relates to the stability and safety of automation systems (operational technology - OT), on the one hand from controls to the servers and on the other, from the servers to the operating stations. Moreover, in view of the fact that an increasing number of “external” accesses to the automation network such as data logging, office use and remote maintenance have become necessary, we recently began to also focus on these issues. We offer the planning of new networks, the adaptation and modification of existing networks, the operation of industrial networks, remote maintenance management and error searches in industrial networks.
Functional descriptions (written or verbal) serve as a basis for control applications, function plans and interlock diagrams, or existing control applications.
A&C transcribes verbal, functional descriptions into written form, which are then presented to the customer or the operator for examination and approval. In the case of pure migration projects (the 1:1 substitution of the controls, the replacement of an old PLC with an up-to-date control system without an increase in speed or the integration of other areas, machines or functions), on the basis of an existing PLC application (or solely using the existing circuit diagrams and input/output card assignments), a detailed function check and documentation are completed, partly in teamwork with the operator.
We program the application software for the process control systems and the PLC, which are then tested by the programmers themselves (during factory acceptance tests (FATs) or site acceptance tests (SATs) with or without the customer or operator).
For the operating surfaces (human machine interface (HMI)), we prepare proposals, which are presented to the customer for examination and approval. These are then scrutinized during testing and released for commissioning in the plant. A&C always attaches great importance to the fact that the programmers put their own applications into operation. As a result, the customer has the same contact partner from the beginning to the end of the project, which avoids software concepts being once again altered completely on the construction site.
Depending upon the scope of the project, the programmer spends a few days on site following commissioning in order to accompany the production processes. All of these are to be tested by the customer along with any variations and this allows the pinpointing and correction of any functional errors.
Basic Engineering:
At the beginning of a project, we deal with all the most important aspects of the plant planning during personal discussions with the customer. Mutual trust is created through the constant flow of information between the customer and A&C and misunderstandings are thus avoided.
Detail Engineering:
Owing to their experience, our designers are able to think in interdisciplinary terms and therefore other areas of activity are also accounted for during detailed planning. Documentation is prepared for new plant, the modification/enlargement of existing capacity and retrofitting. This takes place in line with all relevant standards and regulations and concurrently with the project and not first at its conclusion.
A&C supports its customers during the entire duration of E/I&C, greenfield and brown field projects. We determine the current status of an existing plant and examine the required measures. We bring the documentation up to date and integrate it into modern document systems.
We assist our customers with the updating of their E/I&C plant standards and provide recommendations for a version in line with the state of art.
A&C draws up the documentation for E/I&C tenders for its customers and lays out the desired modification measures in advance. The customer thus has an excellent basis for the comparison of the offers received. In addition, the room for interpretation on the part of the bidders is restricted and thus subsequent demands for additional costs are counteracted from the outset.
A&C provides active support during contract negotiations, supplier selection and award discussions. Following order allocation, A&C assists project completion, the coordination between differing suppliers (definition, coordination and adherence to the interfaces between differing suppliers and trades), adherence and management of the project schedule and checks on project milestones.
A&C repeatedly receives customer inquiries about system training. Our approach in this regard envisages workshops with our customers and depending upon actual requirements (operators, maintenance personnel, administrators) and the system installed, we draw up training documentation and prepare a test set-up. This can take place at the customer’s premises using components that it supplies, or in A&C’s offices. From a cost perspective, we see workshops as a project and invoice according to actual expense, or if the training has been clearly defined, we also offer workshops at a flat rate. The calculation basis is always provided by A&C’s time expenditure and not the number of workshop participants.
As a result of the long-term experience of A&C and its personnel with regard to the realization of E/I&C hard- and software projects, we assist our customers throughout the entire course of project completion.
Irrespective of whether pick and place, mounting, palletizing, stacking, part handling, packing, painting, welding or cutting are involved, robots have become a virtually indispensible part of production, logistics and laboratory work, either in collaboration with humans or in combination with other plant sections via interfaces to machine-related controls, superordinated process controls or manufacturing execution systems (MES).
It was precisely here that we as A&C saw potential links, as we have been involved with machine and process control systems for many years and therefore for us, the enlargement of our portfolio to include services in the robotics field was a logical step. We are both an EPSON and a system integrator, and the premium distributor for drag&bot. Moreover, we offer our customers consulting and services relating to the use of robots and their integration into either existing or new production surroundings.
Today, cameras constitute the "eyes" of automation. Machine vision encompasses technologies and methods that enable the image-based, automatic inspection and analysis of applications such as automatic quality control, process control and robot guidance. Accordingly, imaging methods are steadily gaining in industrial importance and the vision market is growing.
AI-based vision systems employ deep learning, which is a machine teaching process. For example, artificial neural networks, algorithms, are modelled to detect
defects, undertake classifications or assess the (surface) quality of workpieces. The algorithms are trained using data and achieve self- improvement through trial and error, which results in a continuous increase in their ability to make their own predictions or decisions.
We design, build and supply camera and sensor-based inspection systems for your desired automation solution and are also pleased to provide consulting support for your project.