PLC control logic for heavy industrial machinery
Software tools for structured text programming, PID tuning, and safety system configuration.
IEC 61131-3 compliant editor for PLC logic. The Structured Text Programming Suite provides a full-featured editor with syntax highlighting, real-time validation, and simulation capabilities. It supports complex arithmetic expressions, conditional branching, and loop constructs essential for hydraulic press sequencing. Engineers can integrate custom function blocks and reuse code libraries across multiple projects, reducing development time and ensuring consistency in safety-critical applications.
Closed-loop tuning blocks for industrial stamping lines. The PID Control Block Library includes proportional, integral, and derivative modules with anti-windup and feed-forward options. Each block is parameterized for rapid deployment on stamping line applications where precise force and position control are critical. The library also offers auto-tuning routines that adapt to varying material thickness and die wear, maintaining consistent cycle times and reducing scrap rates.
SIS configuration tool for forging press safety. The Safety Instrumented System Configurator enables engineers to define safety functions, assign SIL ratings, and simulate fault scenarios for hydraulic forging presses. It supports redundant sensor architectures, emergency stop logic, and diagnostic coverage calculations. The tool generates compliance documentation automatically, streamlining certification for machinery operating in high-risk environments.
Structured text programming, closed-loop PID blocks, and SIS configurations built for high-capacity hydraulic presses and industrial stamping lines — not generic automation tooling.
Our editor compiles directly to the controller without intermediate abstraction layers. Engineers write complex arithmetic, conditional branches, and loop constructs that map one-to-one to press sequencing logic. No hidden overhead, no vendor lock-in.
Each closed-loop block includes proportional, integral, and derivative terms plus feed-forward compensation. Auto-tuning adapts to material thickness variation and die wear on stamping lines, maintaining cycle time within ±2 ms.
Graphical tool to assign safety functions, simulate fault scenarios, and calculate diagnostic coverage for forging press emergency stops. Generates IEC 61511 compliance documentation automatically — no manual spreadsheets.
Pre-built templates for 2oo2 and 2oo3 voting logic, cross-channel comparison, and proof-test scheduling. Reduces nuisance trips while maintaining safety integrity for high-risk hydraulic systems.
Deployed on forging lines producing aerospace and automotive components. Reference installations show 99.6% uptime over 18 months, with mean time to repair under 45 minutes due to structured diagnostics.
One-time configuration cost covers the tool suite and all future updates. No per-controller or per-node charges — scale from single press to entire plant floor without budget surprises.
Common queries about our PLC control logic, PID tuning, and safety system configurations for hydraulic presses and stamping lines.
Structured text (ST) is a high-level PLC programming language defined by IEC 61131-3. In forging press applications, ST allows engineers to write complex sequencing logic, conditional expressions, and arithmetic operations for controlling hydraulic cylinders, valve banks, and auxiliary systems. Our suite provides syntax highlighting, real-time validation, and simulation to streamline development and reduce errors in safety-critical press cycles.
Our PID library includes proportional, integral, and derivative modules with anti-windup and feed-forward compensation. Each block is parameterized for rapid deployment on high-speed stamping lines, where precise force and position control is essential. The library also features auto-tuning routines that adapt to varying material thickness and die wear, helping maintain consistent cycle times and reduce scrap rates.
The configurator is designed per IEC 61511 and supports defining safety functions, assigning SIL ratings, and simulating fault scenarios for hydraulic forging presses. It covers redundant sensor architectures, emergency stop logic, and diagnostic coverage calculations. The tool automatically generates compliance documentation, simplifying certification for machinery operating in high-risk environments.
Yes. The IDE allows you to create and reuse custom function blocks across multiple projects. You can define your own logic, encapsulate it as a reusable block, and share it within your team. This reduces development time and ensures consistency across press control programs, especially when dealing with repetitive sequences or safety interlocks.
Our tools are primarily built for modern IEC 61131-3 compliant PLCs, but we provide migration guides and conversion utilities for legacy platforms. If you are upgrading an older press line, we can help map existing ladder logic or instruction list code to structured text, preserving control behavior while taking advantage of new debugging and simulation features.
You can request an evaluation license by contacting our team at info@kalamatasoftware.com. We typically provide a 30-day trial with full access to the programming suite, PID library, and safety configurator. Our engineers can also schedule a remote walkthrough to demonstrate how the tools apply to your specific press or stamping line configuration.