From individual readings to a useful batch record
A current reading on a machine screen does not tell you what happened earlier in production. When investigating a deviation, you need to know which batch was running, when something changed and which process readings belong with it.
We design the records around your team's questions. That might be a batch overview, trends across a production period or a quality-control report. The data your equipment makes available is the starting point.
A logger for your Allen-Bradley installation
Allen-Bradley includes different controller families. Connecting a CompactLogix or ControlLogix installation requires a different assessment from connecting an older machine. We check the controller, communication module and accessible data before building the integration.
On suitable Logix controllers, EtherNet/IP can provide a route for reading data. We identify the required tags, the named values in the PLC, and how often to collect them. We handle this technical mapping with your machine builder where needed.
Link each reading to the correct batch
Useful records connect process readings to an identifiable production run. We establish how the start and end of a batch are recorded and where its number comes from. If the PLC does not hold that information, we look for another source or a suitable way to enter it.
When several machines are involved, each value still needs a clear link to its line and batch. We align timestamps, units and names so the records can be used together.
- Find batches by number, machine or production period.
- Compare available process readings in trends or overviews.
- Create reports and exports for further analysis or quality control.
Collect data without unnecessary production overhead
The logger reads the agreed data. We test the collection interval, connection load and behaviour during an interruption. Missing readings are visible so an incomplete record cannot be mistaken for a complete one.
The application can run locally and be available to your team in a browser. We configure access and backups and test a full batch with you before the system becomes part of daily work.
What does an Allen-Bradley batch logger cost?
The main factors are the number of controllers, available connections and required reports. Linking batch identifiers to data from other systems also affects the work involved.
We first discuss what you need to retrieve, then assess the connection. You receive a proposal for an initial working solution. One line can be the starting point, with more machines and reports added later.
Related work by GSD
For a Siemens production environment, we built local batch registration, live monitoring and integrated HMI viewing. These cases show how such an application can help your team. An Allen-Bradley installation requires a separate assessment and development of its controller connection.
Frequently asked questions
Can you connect CompactLogix and ControlLogix?
We assess the connection to your CompactLogix or ControlLogix controller. Its version, network configuration and accessible tags determine how to build the logging solution. The brand name alone does not establish compatibility.
Can you connect older Allen-Bradley PLCs?
We assess each installation. Older controllers may need a different communication module or an intermediate solution. We explain the options and costs before development.
Do we need to replace our current machine screens?
Batch logging usually does not require replacing the operator interface. The logger can provide a separate web application alongside it. If you want HMI screens included, we assess that connection separately.
Can the data stay at the factory?
Yes. We can run the records and web application on a local server. Access from other locations is arranged separately.