PLC Programming Daimler Powertrain
Are you carrying out an implementation in the area of powertrain assemblies for the automotive industry and looking for experienced engineers? We specialize in creating PLC and robot controller software based on Daimler Powertrain standards. As a proven service provider for integrators and machine designers, we guarantee transparent code architecture, efficient commissioning, and trouble-free acceptance during technical inspections.
What does Daimler Powertrain-standard PLC programming include?
We provide PLC software tailored to the specifics of Daimler Powertrain. We build systems that seamlessly connect plant automation with the plant IT network, preparing the line for a trouble‑free final acceptance.
Why entrust us with Daimler Powertrain PLC programming?
We combine precise knowledge of the standard with the practical experience gained from work on facilities. When programming PLC controllers, we provide solutions that fit perfectly within the Daimler Powertrain framework, while also keeping in mind the operational requirements of the production halls.
Predictable implementation
We follow clear procedures at every stage of the project. Thanks to this, we minimize the risk of delays and efficiently go through the entire start-up.
Partnership approach
We operate in such a way that working with us is simple and predictable for your team. We ensure smooth on-site communication and substantive support at every stage of implementation.
Experienced team
We do not delegate work to random subcontractors. From the analysis of assumptions to on-site commissioning, the project is managed by our in-house specialists.
Do you need support with Daimler Powertrain-standard PLC programming?
Selected technologies we use for Daimler Powertrain PLC programming
The Daimler Powertrain standard clearly defines the permitted hardware and software platforms. We implement projects based on approved environments, guaranteeing full conformity of the system with the group’s guidelines.
PLC software and engineering environments
Creating dedicated control logic in the Siemens TIA Portal environment for the S7-1500 family using Siemens ProDiag automatic diagnostics mechanisms. Consideration of process simulations (SIMIT/Virtual Commissioning) and migration from older control platforms.
HMI visualization and operating modes
Designing operator interfaces in Siemens WinCC and Sinumerik environments based on the official Daimler Powertrain graphical libraries and templates. Implementation of unified handling of operating modes.Powertrain Operating Mode Concept and standardized failure diagnostics.
Industrial robotics
Integration and programming of industrial robots (KUKA, FANUC, ABB) in accordance with corporate specifications. Implementation of dedicated communication packages, optimization of motion trajectories, and configuration of safety functions for assembly stations and automated process cells.
Equipment and technological processes
Programming of communication for multi-channel screwdriver controllers (Cleco, Atlas Copco, Desoutter), press stations (Kistler maXYmos), measurement systems (Marposs), industrial scales (Minibea Intec) and adhesive and sealant application stations.
Drives and positioning systems
Configuration and parameterization of frequency converters and servo drives based on Siemens SINAMICS and SEW‑Eurodrive solutions. Seamless data exchange based on the PROFINET protocol with support for precise axis synchronization and technological positioning.
Vision systems, identification and Traceability
Implementation of RFID read and write systems (e.g. Siemens SIMATIC RF300, Balluff) according to the specification Daimler Tag Layout as well as vision sensors and scanners for detail verification and DMC/2D code reading, including Sensopart, Cognex, Keyence.
Integrated safety apparatus
Implementation of secure communication over the PROFIsafe bus with support for interlocked protective guard locks including, among others, the Euchner MGB, laser scanners, light curtains and Safety Integrated zone functions protecting operators at manual and automated stations.
Higher-level interfaces and IT
Configuration of dedicated communication interfaces connecting PLC controllers with the plant MES system, process databases (IPM, ZellSystem, Prisma, PLA) and SCADA stations.
Are you looking for a trusted partner to deliver advanced automation built to automotive standards?
Consult your Daimler Powertrain project.
Processes and areas that we program in the Daimler Powertrain standard
We create software for automated lines and manual workstations in the production of drive assemblies. We provide motion precision, reliable quality control and full traceability of components.
Mechanical processing of housings and drive components
Programming of machining and loading stations for blocks, heads and housings. Full integration of metrology systems along with downtime diagnostics in Siemens ProDiag.
Assembly of engines and gearboxes
Control logic for the final assembly line based on Powertrain Operating Mode Concept. We implement strict Poka-Yoke interlocks that prevent the omission of any assembly step.
Components of electric drives
Assembly stations for rotors, stators and module housings. We include dedicated test procedures with rigorous adherence to high-voltage (HV) safety.
Pressing and ironing
Servo press control with real-time analysis of force-displacement curves. Assessment of the tolerance window with automatic station lockout and immediate rejection of defective parts.
Threaded connections and tightening
Integration of multi-channel screwdriving controllers over PROFINET. Torque and angle monitoring with assignment of the full tightening profile to the part identifier.
Dosing and application of sealants
Sealant and adhesive application stations with continuous monitoring of pressure and flow. Integration with robots and vision systems for immediate control of the bead path.
Tightness tests and control stations
Pressure trials and leak tests with automatic blocking of defects. Recording NOK results on a data carrier and directing the part to the repair station.
Semi-automatic stations with operator guidance
Logic for manual workstations with on-screen instructions and pick control (Pick-to-Light). Interfaces based on the official Daimler HMI library and hardware safety interlocks.
Technological transport and sequencing
Control of conveyors and automated guided vehicles on approved drives. Safe communication based on the PROFIsafe protocol and unified data exchange interfaces.
Component tracking and quality control
Identification of parts (RFID, 2D codes) and transmission of process data to higher-level systems. Compliance with Daimler Tag Layout for the guarantee of smooth communication with the plant MES system.
How do we work with our clients?
We tailor the form of cooperation to the needs of the enterprise and the requirements of the given implementation. We propose two clear models of division of tasks.
Model 1: Support as a subcontractor
We supplement the competencies of your engineering team. We take over an assigned portion of programming work and assist during the start-up of machines on site. This solution is designed for companies that want to secure the implementation of a project in the face of tight deadlines.
Model 2: Comprehensive turnkey implementation
An offering for companies that prefer to transfer full responsibility for the software to a single supplier. We are responsible for the entire cycle – from requirements analysis, through software architecture, integration of robots and equipment, to on-site commissioning, optimization, and handover of the station for operation.
Industry leaders trusted us
Star Assembly LLC
Sebeș, Romania
Audi
Gyor, Hungary
BMW
Steyr, Austria
Stellantis
Mirafiori, Italy
BMW
Dingolfing, Germany
Daimler
Brühl, Germany
NIDEC
Niepołomice, Poland
Skoda
Mlada Boleslav, Czech Republic
Liebherr
Bischofshofen, Austria
Festo
Budapest, Hungary
Daimler
Untertürkheim, Germany
Dana
Amal, Sweden
Scania
Södertälje, Sweden
Volkswagen
Polkowice, Poland
Volkswagen
Salzgitter, Germany
Daimler
Redford, USA
Daimler
Kassel, Germany
Getrag
Cologne, Germany
Getrag
Bordeaux, France
Daimler
Jawor, Poland
Bosch
Charleston, USA
Magna
Tychy, Poland
ZF
Toluca, Mexico
JLR
Wolverhampton, Great Britain
Examples of projects carried out in the Daimler Powertrain standard
Production line of the eATS2.0 electric motor – Daimler A.G.
Ask about engineering support for projects according to the Daimler Powertrain standard.
FAQ – Frequently Asked Questions
Which technological processes do you program in the Daimler Powertrain standard?
We support the full range of stations and production lines dedicated to powertrain assemblies – from mechanical machining of engine housings and gearbox casings, through final assembly of combustion engine units, to E-Drive areas (assembly of stators, rotors and HV packs). We implement logic for automated robot cells and semi-automatic stations with operator guidance. We program advanced technological processes, including multi-spindle tightening, press-fitting with force-travel analysis, leak tests, seal application, as well as transport (AGVs, conveyors) and integration of part identification and tracking systems.
How, step by step, does the implementation of a project proceed in the Daimler Powertrain standard?
We begin the implementation with an analysis of the specifications and verification of the software architecture for full compliance with the company’s guidelines. A dedicated technical lead establishes the schedule, the cooperation model and the precise division of tasks. Our engineers prepare the code using proven procedures and checklists. The final phase comprises on-site acceptance tests, cycle time optimization, integration of the station into the production process and engineering assistance until a stable start of production.
What does the cost of PLC programming in the Daimler Powertrain standard depend on, and what does the pricing look like?
The final project budget depends on the number of PLC controllers, HMI panels, robots and process equipment, the degree of complexity of the technological processes, the chosen cooperation model (subcontracting vs. turnkey) and the scope of integration with the plant’s IT environment. We prepare the estimate individually based on an audit of the technical specification, the functional documentation and the equipment list from the plant’s Freigabeliste.
Do you provide on-site support during site commissioning and SAT technical acceptance tests?
Yes, the presence of our engineers on the investor’s premises is a key element of our service. The team implementing the project is responsible for signal testing, technological commissioning, integration of peripheral devices, conducting SAT acceptance procedures, and technical assistance during the line start-up. We provide on-site support until full production readiness is achieved and the official final acceptance.
Are training sessions for maintenance staff and operators conducted as part of the implementation?
Yes, after the implementation work is completed, a cycle of training sessions is conducted for maintenance engineers and station operators. The scope includes operation of operator interfaces, interpretation of Siemens ProDiag diagnostic messages, and procedures for rapid fault removal on HMI panels, which enables the plant team to operate the installation independently.
Will we receive access to the PLC and HMI source code after the implementation is completed?
Yes, after the final technical acceptance we hand over the complete project to the investor or integrator. The software is fully structured and documented in accordance with the requirements of the Daimler Powertrain standard, which enables the plant’s technical services to freely perform diagnostics, carry out ongoing maintenance, and potentially expand the line in the future.
Do you also deliver projects compliant with the Daimler Integra standard?
Yes, we deliver PLC programming in line with the Daimler Integra standard across all production areas in Mercedes-Benz plants. We execute projects for body shops, paint shops, final assembly, and intralogistics systems.
Contact us – we will respond within 24 hours!
Do you have questions regarding PLC programming in the Daimler Powertrain standard? Fill out the contact form, and our team will contact you within 24 hours – by phone or email.
During a conversation or correspondence we will jointly determine the scope of the work and services you are interested in. Then we will conduct an internal analysis of your inquiry in order to prepare the best possible solution.
We will get back to you within a maximum of 5 business days with information about the next steps.
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