Who is A&C?

A&C Automationssysteme & Consulting GmbH was founded in 1979 as Leo Stadlmayr Electrical & Control Systems.
We are an engineering office in the field of industrial system automation and we offer our services worldwide. Our expertise spans many different industries and automation systems and our range of services is continually expanding.

Our services

A&C provides E/I&C services in the field of industrial system automation. Our services include consulting, hardware- and software-Engineering, turnkey-projects, interfaces, … More

Our systems and tools

Over time, we have continually expanded the portfolio of systems and tools we use. Browse here for an overview.

Turnkey projects

In addition to the services described above, A&C also delivers turnkey projects. These could be, for example, process control systems with several process controllers and server-client systems for operation and data archiving, PLC-based machine controllers, migrations… More

Migrations

Experience shows that production machines and processing systems often have a longer lifecycle than the switchgear and systems controlling them. Spare parts are not available or can only be found used, there is no scope for expansion, or maybe you have plans to implement new functions. We offer a comprehensive range of services for plant modernisation. A new switching station and the automation it brings can considerably improve machine availability and yield… More

Industrial networks

When it comes to networks, our expertise lies in ensuring the stability, security and reliability of automation networks, both from controllers to servers and from servers to operating stations. We started focusing on these aspects quite some time ago, when we witnessed the increasing need for “outside” access… More

Software applications

We develop control applications working from written or verbal functional descriptions, functional plans, interlock diagrams, or old control applications.
A&C takes verbally communicated functional descriptions and writes them out before presenting them to the customer or operator for checking and confirmation. Pure migration projects … More

Hardware planning

At the beginning of each project, we run through all important points of the plant design in a face-to-face meeting with our customers. The experience of our engineers gives them the benefit of transdisciplinary thinking. Thus during the detail planning, they know which other trades to take into consideration… More

Consulting

A&C assists its customers throughout the entire course of an E/I&C project – in greenfield and brownfield projects alike. We survey the initial situation of an existing plant and determine what measures will be necessary… More

Robotic

Whether in assembly, palletizing, stacking, parts handling, packaging, painting, welding, cutting, … . Robots are virtually indispensable in production, logistics or the laboratory environment, … More

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Our services

A&C provides E/I&C services in the field of industrial system automation.

A&C offers these services either on a per-item basis or in the scope of a clearly defined, fixed-cost project. We work with the common CAE systems, process control systems (PCS) and programmable logic controllers (PLC) and primarily in the paper, steel, plastic and coatings,

cement, automotive, intralogistics/conveyor technology and woodworking industries. Through our activities in these areas, we also amassed a great deal of experience in the industries of energy, wastewater treatment and continuous processes in general.

Our systems and tools

Over time, we have continually expanded the portfolio of systems and tools we use. Browse here for an overview.

Turnkey projects

In addition to the services described above, A&C also delivers turnkey projects. These could be, for example, process control systems with several process controllers and server-client systems for operation and data archiving, PLC-based machine controllers, migrations (e.g. replacing an outdated controller with a successor model or a PLC from another manufacturer), integration of new machine parts into existing process control systems, or even customer-specific camera/sensor-based inspection systems.

Process control systems
A&C plans hardware and software solutions to meet the customer requirements and specifications. Control, periphery and computer cabinets are planned by A&C and built by longstanding partner firms. The latest in process control systems even facilitate this process with OS-level virtualisation capability. We can furthermore compare the pros and cons and the pricing differences between virtualisation and a conventional environment, to help the customer decide which system is best suited.
After the engineering phase, A&C prepares the corresponding test environment as a simulation or in actual hardware, and runs through the testing of this environment together with the customer. Once all tests have been successfully passed, the commissioning phase begins.
We like to include our customers throughout the multiple phases of engineering, testing and commissioning – on the one hand because it keeps the project costs low and, on the other hand, because it greatly facilitates future maintenance and minor adaptations to the process control system for the customer.

PLC, machine control systems
Just as with process control systems, A&C plans the hardware and software according to customer requirements and specifications. Control and periphery cabinets are planned by A&C and built by longstanding partner firms. Built-in control panels or PCs are employed as user interfaces.

Testing and inspection machines
Depending on our customers’ requirements, A&C creates concepts for testing and inspection machines based on cameras or sensors. These are either integrated into ongoing production processes (with a connection to existing controllers, process control systems or OPC servers) or installed as standalone solutions with their own controller and operating unit – always depending on what the respective customer needs or the production process demands.

QCS, cross-machine and machine direction profile control
Originally developed for coating board web for beverage packaging, our PCS-7-based cross-machine and machine direction profile control is now universally used in both paper and board machines. A&C’s QCS application is programmed in SCL. While it has so far been used predominantly in PCS 7 environments, the code can also be ported to other PCS or PLC environments.

Migrations

Experience shows that production machines and processing systems often have a longer lifecycle than the switchgear and systems controlling them. Spare parts are not available or can only be found used, there is no scope for expansion, or maybe you have plans to implement new functions. We offer a comprehensive range of services for plant modernisation. A new switching station and the automation it brings can considerably improve machine availability and yield.

We offer migrations for conveyor, bottling, bag-filling and palletising plants, saw equipment or sawmills, and sorting machines, at a fixed price if desired.

  • Document revision

    During a migration is the perfect time to bring all documents up to date. A&C will update your existing electrical documentation, or we can assemble new switchgear, which we will then swap out for you.

  • Adaptation of the operational and safety concept

    When changing the software of a plant, it is also crucial to re-evaluate the dangers for the operating personnel. It is also a good occasion to adapt and amend the operational concept.

  • Reprogramming and expansion

    Reprogramming and expansion

  • Interfaces to other systems

    Naturally, the existing systems have to get along well with the “newcomers”. A&C adapts and tests all interfaces to make sure this is the case.

Industrial networks

When it comes to networks, our expertise lies in ensuring the stability, security and reliability of automation networks, both from controllers to servers and from servers to operating stations. We started focusing on these aspects quite some time ago, when we witnessed the increasing need for “outside” access in the form of remote operational data queries, office accesses and remote maintenance. Services we offer include planning new networks, adapting and rebuilding existing networks, operating industrial networks, remote maintenance management, and troubleshooting in industrial networks.

Software applications

We develop control applications working from written or verbal functional descriptions, functional plans, interlock diagrams, or old control applications.
A&C takes verbally communicated functional descriptions and writes them out before presenting them to the customer or operator for checking and confirmation. Pure migration projects (1:1 replacement of the controller – superseding an outdated PLC with an up-to-date control system – without any speed increase or inclusion of additional trades, machines or functions) based on an old PLC application (or based merely on existing circuit/wiring diagrams and I/O card pinouts), involve performing a detailed functional check and functional documentation, sometimes together with the operator.
The application software for the process control systems and PLCs are programmed by us and tested by the programmers themselves (in the scope of an FAT (Factory Acceptance Test) or SAT (Site Acceptance Test), with or without the customer or operator).

For the HMI (Human Machine Interface), we develop suggestions and submit these to the customer for verification and approval. The HMI also undergoes testing and approval for commissioning in the system. A&C makes an important point of ensuring the programmers personally commission their own applications. This means the customer can communicate with the same contacts throughout the entire project, and avoids the risk of software concepts being completely overturned once they are on site.
For a few days after commissioning onsite, depending on the scale of the project, the programmer remains onsite to provide support during production. During this period, the customer is asked to run through all production processes and variants for testing. This way, any malfunctions are discovered and eliminated.

Hardware planning

Basic engineering:
At the beginning of each project, we run through all important points of the plant design in a face-to-face meeting with our customers. A constant flow of information is established between the customer and A&C, thus building trust and avoiding misunderstandings.

  • Concepts for system automation and operation
  • Creation of requirements/performance specifications
  • Definition of functions, including creation of function charts
  • Device specifications, from field device to PCS

Detail engineering:
The experience of our engineers gives them the benefit of transdisciplinary thinking. Thus during the detailed planning, for example, they know which other trades to take into consideration. No matter what the scale of the project – be it a new system, modification/expansion of an existing system, or retrofitting – the necessary documentation, compliant with all relevant standards and regulations, is generated in throughout the entire project, and not merely at the end.

  • Planning of switch and control cabinets and field distributors
  • Field-side planning of control and indicator systems
  • Creation of hook-ups
  • Planning of field bus systems
  • Proof of the necessary Safety Integrity Level (SIL)
  • Provision of circuit and wiring diagrams, terminal diagrams, and wire and parts lists

Consulting

A&C assists its customers throughout the entire course of an E/I&C project – in greenfield and brownfield projects alike. We survey the initial situation of an existing plant and determine what measures will be necessary. We bring documents up to date and port them to modern documentation systems. Furthermore, we provide our customers support in updating their E/I&C works standards, and give recommendations for how to do so in line with the state of the art.
A&C develops E/I&C tendering documents for its customers, and itemizes the desired restructuring measures in advance. The customer thus has an excellent basis for comparing the incoming proposals. There is also less room for misinterpretation for the proposer, thus reducing the likelihood from the outset that any additional charges will be claimed later.
A&C provides active assistance in contract negotiations when selecting suppliers and awarding negotiations.
After awarding, A&C assists the project management in coordinating between various suppliers (definition and coordination of and adherence to the interfaces between different suppliers or trades),

regarding adherence to and control of the project schedule, and in the verification of the project milestones.
Customers repeatedly approach A&C for system training. Our approach is to hold workshops with our customers. Depending on the specific needs (operators, maintenance, administrators) and based on the specific system installed on the customer’s premises, A&C compiles training documents and prepares a test structure for the workshop. This can be done either on the customer’s premises using components provided by the customer, or at the A&C office. The workshops are budgeted in the manner of projects. Pricing for the workshops is either calculated at expense or, if the goals are clearly defined in advance, set at a fixed price. The basis for this is always the time put in by A&C, not the number of workshop participants.
We assist our customers during the entire course of the project with all of the longstanding project experience of the company A&C and its employees in the implementation of E/I&C hardware and software projects.
 

Robotics

Whether in assembly, palletizing, stacking, parts handling, packaging, painting, welding, cutting, … . Robots are virtually indispensable in production, logistics or the laboratory environment, either collaborating with humans or in conjunction with other plant components via interfaces to machine-oriented controls or to higher-level process control systems or to the MES (Manufacturing Execution System).
And this is exactly where we see the starting point as A&C. We have been dealing with machine control and process control systems for decades, so it was a logical step for us to expand our portfolio to include robotics services. We are EPSON Integrator and offer our customers consulting and services around the use of robots and their integration into an existing or new production environment.