However well a machine’s mechanics are designed, if the operator’s screen and the software that runs the machine do not do their job, neither does the machine. DKT Design and Software develops control software for machines: PC-based software that communicates with the machine’s PLC, is easy for operators to use and records production.
What does machine software include?
- Operator screen: A touch-friendly interface showing the machine’s status, sensors and motors.
- Recipe and parameter management: Saving product-specific settings and limiting who may change them.
- Automatic cycle: Running the machine’s steps in sequence and safely.
- Alarms and event log: Showing faults immediately and keeping a history.
- Production records and reports: Logging production, with reports that open in Excel.
- User permissions: Different access levels such as operator and service.
- Simulation mode: Testing the software without a PLC, before the machine exists.
Communication with the PLC
Our software communicates with the PLC over Modbus TCP. The machine’s input/output map is not hard-coded; it is defined in a separate file, so when the machine changes, the file changes, not the code. This lets the same software platform be adapted to different machines quickly.
How is machine software developed?
- I/O list: The machine’s sensors, motors, valves and PLC type are listed.
- Operating sequence: How the machine works step by step, with interlocks and safety conditions, is put in writing.
- Screen design: The screens and menus the operator will use are designed.
- Software and simulation test: The software is developed and tested in simulation mode without connecting to a PLC.
- Commissioning: Inputs and outputs are tested one by one on the machine, settings are made and operators are trained.
PC-based software or an operator panel?
For small, simple machines an operator panel (HMI) connected to the PLC is often enough. Where a machine needs recipe management, production records, reports and large, clear screens, PC-based software offers more: storing data, producing reports and updating the software are easier. We choose the right setup together based on your machine’s needs.
Examples in the field
Our DKT CPlants concrete batching plant software and DKT APlants asphalt plant control software, developed with this approach, are our products for heavy-industry plants; APlants runs at an asphalt plant in the field.
We also develop the machine vision and AI software of our welding robots: the camera tracks the seam and AI recognises the welder’s chalk mark. Details: welding robots with machine vision.
With the design or on its own
We can develop the software as part of a machine we design, or to replace the outdated software of an existing machine. We explain how mechanical design, animation and software work together on our engineering services page.
Machine software pricing
The price of machine software depends on the number of I/Os and screens, recipe and report requirements, PLC communication and the time needed for commissioning on site. Details are on our pricing page.
Frequently asked questions
Which PLCs do you work with?
Our software communicates with the PLC over Modbus TCP, so it can work with PLCs that support Modbus TCP. Share your machine’s PLC and I/O list and we will check compatibility together.
Can you replace the software of my existing machine?
Yes. The PC software that talks to the PLC can be renewed without touching the machine’s mechanics or control panel.
Can you test the software before the machine is ready?
Yes. The software runs in simulation mode without connecting to a PLC, so it is prepared and tested while the machine is being built.
Does the operator screen work on a touch screen?
Yes. The interfaces are designed for touch use.
Related pages
- Engineering services
- Machine design
- Kinematic analysis and animation
- Automation retrofit without touching the panel
- PLC connection with Modbus TCP
- Welding robots with machine vision
- AI welding robot
Tell us what your machine’s software needs
The PLC type and I/O list are enough to start; we will work out compatibility and scope together. WhatsApp: +90 547 909 99 90 · info@dokuti.com