S and T ControlsCase study · Controls & PLC
Body Shop Cell PLC & HMI Programming
Developing and debugging Studio 5000 PLC and HMI programs for five automotive body shop cells.
- My role
- Project Controls Engineer
- Timeframe
- S and T Controls · Mar 2023 – Jul 2023
- Team / context
- S and T Controls, Kitchener, ON, Canada
- Tech stack
- Allen-Bradley Studio 5000 · PLC · HMI · Wiring diagrams · Schematics
01
Overview
At S and T Controls I developed and debugged the Studio 5000 PLC and HMI programs for five body shop cells, and verified their wiring diagrams.
Body shop cells build the vehicle's structure. Their PLC logic sequences the equipment, their HMI lets people run and recover them, and their wiring diagrams tie it all to physical hardware.
I worked from each automated process's scope and requirements, reviewed the wiring diagrams and schematics of the automated cells, debugged logic errors and faults in Studio 5000, and coordinated with senior engineers and the project manager to deliver the project on time.
02
The problem & objective
Five body shop cells needed working control software and accurate electrical documentation.
03
My role & responsibilities
Project Controls Engineer. Delivered as part of my role as Project Controls Engineer at S and T Controls.
- Develop PLC programs in Studio 5000 for 5 body shop cells
- Develop HMI programs for the same cells
- Debug logic errors and faults in the PLC and HMI programs
- Review and verify the cells' wiring diagrams and schematics
- Work from each automated process's scope and requirements
- Coordinate with senior engineers and the project manager
04
Approach & process
Understand the process
Start from each automated process's scope and requirements.
Develop the PLC logic
Program each cell in Allen-Bradley Studio 5000.
Develop the HMI
Build the operator interface for each cell.
Debug
Find and fix issues in the PLC and HMI programs.
Verify wiring diagrams
Check the wiring diagrams so hardware and software agree.
Coordinate delivery
Work with senior engineers and the project manager to keep the project on schedule.
05
Key features & deliverables
PLC programs
Studio 5000 programs for 5 body shop cells.
HMI programs
Operator interfaces for the same 5 cells.
Verified wiring diagrams
Wiring diagrams verified for all 5 cells.
06
Challenges & how I solved them
| Challenge | How I solved it |
|---|---|
| Software and hardware must match | Verifying the wiring diagrams alongside developing the programs keeps the logic and the physical wiring consistent. |
07
Results & impact
- PLC and HMI programs developed and debugged for 5 body shop cells
- Wiring diagrams verified for all 5 cells
08
Skills demonstrated & lessons learned
Skills demonstrated: Studio 5000 · PLC programming · HMI development · Debugging · Electrical documentation
Controls software is only as reliable as the documentation underneath it.
Get in touch
Let's work together
I'm open to Controls Engineer, Automation Engineer, Software Engineer, and Full-Stack Developer roles, remote or on-site. If you're building something where automation and software meet, I'd like to hear about it.
elshark.atef@gmail.com