#messung industrial automation & control system

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Smarter Surface Protection – PLC Automation in Autophoretic Coating Plants

In modern manufacturing, surface coating is not just cosmetic—it’s essential for durability, corrosion resistance, and performance. Autophoretic coating (also known as A-coating) has emerged as a water-based, eco-friendly alternative to electro-coating. When combined with PLC-based automation, it becomes a powerful, scalable solution for high-quality, uniform metal finishing.

Because let’s face it—metal without proper protection is like a knight without armour. In today’s industrial world, that armour comes in the form of surface coating. And when it comes to smart, sustainable, and scalable coating, autophoretic coating is the unsung hero.

But wait, here’s where it gets exciting. Pair this eco-warrior coating with PLC automation, and what you get is nothing short of magic. At Messung Industrial Automation, we believe that the perfect coat is not just about shine—it's about smarts, speed, and sustainability.Let’s dive into the world where chemistry meets code, and surface protection meets the future.

What is Autophoretic Coating?

Autophoretic coating, also known as A-coating, is a process where metal parts are dipped in a reactive water-based solution. The result? A self-depositing layer forms on the surface, without any electric current. Unlike traditional methods that zap the surface with electricity, A-coating lets chemistry take the wheel.

Why Are Industries Making the Switch?

Industries are coating their bets on it because it avoids the need for heavy electric setups and provides uniform coverage even in complex geometries.  Since it is water-based, it is also very environmentally friendly.

Where Is It Being Used?

From under-the-hood car parts to refrigerator frames, autophoretic coating is making waves in:

Automotive parts

Appliance components

Agricultural and construction machinery

General industrial structures

In an age where efficiency, sustainability, and performance go hand in hand, autophoretic coating emerges as a transformative solution. Its simplicity belies its power, ushering in a cleaner, smarter way to protect surfaces without compromising on quality or cost. As industries across the board continue to embrace greener practices, A-coating, powered by automation and intelligence, is painting the future—one seamless coat at a time.

 Role of PLC in the Coating Plant

In the realm of autophoretic coating, precision isn't a luxury—it's a necessity, and that precision begins with the silent genius of automation: the Programmable Logic Controller (PLC). Think of the PLC as the central nervous system of your coating plant—connecting, communicating, and commanding every mechanical muscle with machines. Here is how PLCs turn a basic coating line into a harmonious dance of efficiency and intelligence.

Precision Process Automation

A modern autophoretic coating plant runs smoothly like a well-coordinated team, and the PLC (Programmable Logic Controller) is in charge. It doesn’t just control the machines—it helps everything work perfectly together. From:

Tank temperature

Solution pressure & pH levels

Cycle timing for each dip and rise

...every step is monitored and controlled by PLC automation.

Material Handling Magic

Using intelligent material handling controllers, our PLC guides parts through multiple stages:

Degreasing

Surface conditioning

Coating dip

Rinsing & curing

Like a choreographer directing a ballet of metal.

Circulation & Filtration Mastery

Good coating = Consistent flow. Our process controllers and PLC control systems manage:

Fluid circulation

Filtration cycles

Solution replacement timing

Synchronisation with Process Controllers

Through seamless synchronisation with motion control systems, everything moves with precision. No drips, no downtime.

In an industry where milliseconds matter and uniformity is sacred, PLC automation elevates the autophoretic coating plant from functional to phenomenal. It enables not just control, but clarity—ensuring that every part, every dip, and every process flows with intelligent intent.

NX-ERA JET PLC System Architecture

Our flagship—NX-ERA JET PLC—is a robust, real-time, and rugged automation genius. It’s compact, reliable, and battle-tested in industrial heat.

Talk the Talk: MODBUS & TCP/IP

Built-in PLC communication protocols like:

MODBUS TCP/IP

MODBUS RTU

Make it plug-and-play with SCADA and automation systems. Yes, it speaks fluent-machine.

Ethernet-Based Controllers for High-Speed Sync

Using Ethernet-based controllers, data flows like molten metal. Zero lag, maximum productivity.

HMI with PLC Controllers

With user-friendly HMIs with PLC controllers, even a non-techie can operate complex coating sequences. Tap, drag, drop—and coat!

From seamless communication to intuitive control, the NX-ERA JET PLC is more than just a controller—it's the central nervous system of your autophoretic coating plant. With its advanced architecture, lightning-fast data sync, and plug-and-play compatibility, it transforms complexity into clarity. Whether you're scaling up or starting smart, this system offers the flexibility, durability, and intelligence your operations demand.In a world where precision meets pressure, the NX-ERA JET PLC ensures your plant doesn’t just perform—it excels.

Advanced PLC Automation for Smart Manufacturing

In the age of Industry 4.0, surface coating is no longer just about chemistry—it's about intelligence, precision, and adaptability. That’s where advanced PLC automation steps in as the invisible powerhouse behind your plant’s performance. Whether you're scaling up operations or streamlining a compact facility, smart automation is the lever that elevates your process from ordinary to outstanding.

Let’s uncover how Messung’s cutting-edge PLC technology is revolutionising autophoretic coating plants with flexible, responsive, and future-ready control systems.

Modular, Compact & Ready to Go - Whether it’s a big plant or a small-scale setup, our Modular PLC, Compact PLC, and Smart PLC configurations give you tailor-made flexibility.

Motion Control with Millisecond Precision - Our motion control systems enable synchronised movement, avoiding delays or overlaps in the coating sequence.

Material Handling - Our embedded material handling controllers do the heavy lifting—literally—without breaking a sweat.

This isn't just automation. This is smart automation that thinks ahead, moves with purpose, and adapts to demand. With Messung’s PLC-powered intelligence, your coating plant doesn’t just run—it evolves.

Because in the world of advanced manufacturing, it’s not just about staying ahead—it's about setting the pace.

Smart. Sustainable. Secure: The Evolution of PLC Automation in Coating Plants

In the era of Industry 4.0, coating plants need more than just control—they need intelligence, integration, and intention. Here’s how Messung’s PLC automation is redefining autophoretic coating systems:

Built for Harsh Industrial Realities – Our Industrial PLCs endure dust, moisture, heat, and vibration. Conformal-coated PLCs protect against corrosive chemicals in A-coating zones and provide long-lasting performance in extreme environments.

Safety Meets Smarts - PLCs are integrated for emergency stops, controlled shutdowns, and real-time fault alerts with logs, making them smart, secure, and always in control.

Welcome to Industry 4.0-Based Controllers

PLC with IoT for remote monitoring and real-time plant access.

MQTT-based PLCs for cloud-friendly, lightweight data communication.

Full PLC system integration with BMS, SCADA & more—ensuring a harmonious automation ecosystem.

Green Gains: Eco-Friendly A-Coating Automation

Water-based chemistry reduces VOCs and emissions.

Smart PLCs optimize dosing & disposal—minimising waste, maximising results.

Cleaner air, cleaner conscience, smarter coatings.

With Messung’s intelligent PLC, you don’t just automate—you evolve. Sustainable, scalable, and secure—this is the new face of PLC-based automation solutions in A-coating.

Business Benefits of PLC-Based Automation Solutions

In today’s hyper-competitive manufacturing world, success isn’t just about innovation—it’s about consistency, efficiency, and scalability. This is where PLC-based automation doesn’t just support your coating process—it transforms it. Let’s explore how Messung’s smart automation systems turn operational goals into tangible business advantages.

Uniformity Every Time - When every product must meet the same high standard, there’s no room for guesswork. Thanks to PLC control systems, your coating process is even, repeatable, and of high quality. 

Never any Downtime - Time is money, and downtime is a thief. With real-time monitoring and intelligent automation controllers, potential issues are detected and resolved before they affect production. Fewer breakdowns. More uptime. Happier bottom line.

Easy to Maintain & Scale - Growth shouldn’t be a gamble. With built-in PLC maintenance alerts, you get proactive notifications that prevent surprises. Want to expand operations? Simply plug and play with modular I/O modules. You’re ready for tomorrow—today.

In essence, PLC automation is not just a control system—it’s a business strategy. It safeguards quality, boosts efficiency, and equips your coating plant with the agility to evolve. Because when your process is smart, your performance is unstoppable.

Conclusion: The Final Coat

A surface is only as strong as the system behind it. In the era of smart manufacturing, Messung’s PLC automation solutions empower autophoretic coating plants with unmatched precision, efficiency, and sustainability. From real-time monitoring and advanced PLC control systems to seamless IoT integration and predictive maintenance, our technology ensures optimal surface protection with minimal waste. Whether it’s modular PLCs, industrial automation controllers, or motion control systems, Messung delivers the complete package. So why let inefficiencies corrode your bottom line? Upgrade your coat. Upgrade your process. Upgrade with Messung PLCs—where intelligent automation meets perfect protection.

FAQs

How does PLC contribute to energy efficiency in coating plants?

By optimizing process timings, reducing idle machine hours, and enabling intelligent power management, PLCs help cut down energy consumption and operational costs.

Can PLC automation reduce coating defects?

Absolutely. With real-time monitoring, precision control, and error alerts, PLC automation ensures consistent quality.

How easy is it to integrate Messung PLCs in existing lines?

Very! Our modular PLC systems and versatile PLC communication protocols like MODBUS and TCP/IP allow seamless integration.

Are conformal-coated PLCs necessary?

Yes, especially in chemically aggressive environments like coating plants. They extend the life and reliability of your Programmable Logic Controller.

What industries benefit most from PLC with IoT?

Automotive, general manufacturing, and any industry embracing Industry 4.0-based controllers and smart factory setups.

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What is a Chiller Plant and Why is It Important in Commercial Buildings?

Modern commercial buildings are able to maintain their consistent indoor climate today due to the focus on efficiency and productivity. It is also about sustainability. The chiller plant is at the center of this climate control system. Major commercial complexes like towering office complexes and hospitals, along with data centers, require a quality chiller plant management system. These play an important role in regulating temperature/Humidity and reducing energy costs.

This article will help you have a deeper look into what a chiller plant is. You shall also realize why a chiller plant management system is such an important part of commercial spaces. In this context, companies like Messung BACD are changing the performance landscape through smart automation.

What is a Chiller Plant?

A chiller plant is a centralized cooling system. It is used in large buildings and industrial facilities. It works by removing the heat from the building. The heat is then transferred to the outside environment. All of this is done on a refrigeration cycle. The chiller plant usually has chillers and cooling towers, along with pumps (Primary, Secondary, condenser etc.) at the plant room side and air handling units (AHUs) at the building side. These parts work together to circulate chilled water throughout the building. This, in turn, absorbs heat from indoor spaces and maintains the right temperature levels.

There are various kinds of chillers available. These include air-cooled, water-cooled, and absorption chillers. Each of these is suited to different climate conditions and building sizes. No matter what type of chillers being employed in a facility all chiller plant management systems aim to ensure good thermal comfort while minimizing energy usage.

Importance of Chiller Plants in Commercial Buildings

Let us delve into the importance of chiller plant management systems in commercial buildings:

Temperature Regulation for Occupant Comfort

The most obvious reason to have a chiller plant is to be able to maintain the right temperatures. These need to be comfortable for the occupants. Regions that have hot climates or experience peak summer seasons find this an efficient system. They ensure that employees, customers, and tenants can work/ live in a comfortable environment.

Critical for Heat-Sensitive Environments

Chiller plant management systems are needed in facilities where temperature control is important. Hospitals and laboratories, along with data centers, rely on precise temperature regulation. This is to ensure that the equipment and data remain safe, along with, most importantly, human lives. Even slight deviations in temperature can lead to equipment failure or medical storage compromise in this case.

Energy Efficiency and Cost Control in Large Facilities

It takes a significant amount of energy to cool a large building. This usually accounts for about 40-60% of the overall electricity consumption in commercial buildings. A well-optimized chiller plant management system can greatly reduce the use of energy. As a result, the building incurs a lower utility bill. Since energy costs are rising and newer concerns regarding the environment are coming up, building owners are under pressure to employ only the most efficient cooling systems.

Impact on Indoor Air Quality and Productivity

Chiller systems are indirectly responsible for better indoor air quality. This is done by maintaining optimal humidity levels and supporting ventilation systems. Good air quality ensures enhanced cognitive performance amongst the residents/ occupants with reduced absenteeism. The overall well-being of the occupants is also enhanced in the process. This is particularly important in office buildings and schools.

Sustainability Behind a Well-Designed Chiller Plant

Sustainability is not a simple option anymore. It is an important aspect of chiller plant management systems. Here is how it helps:

Reduced Carbon Footprint

Power plant construction typically has a large carbon impact, which might undermine your sustainability objectives. The total amount of carbon emissions increases with their energy consumption. Effective chiller plant management systems reduce overall energy consumption by using less electricity. This significantly reduces the plant's total greenhouse gas emissions. 

Water Conservation

Many chiller systems rely on cooling towers, which consume large volumes of water. Newer systems can now use less water or recycled water within the plant. This contributes to responsible resource usage.

Integration with Green Building Standards

Buildings that wish to achieve certifications like LEED (Leadership in Energy and Environmental Design) or IGBC (Indian Green Building Council) need to show proof of efficient energy/ water usage. An optimized chiller plant helps significantly in achieving such milestones.

Messung BACD – Revolutionizing Chiller Plant Automation

When it comes to quality chiller plant management system automation, Messung BACD (Building Automation and Control Division) is a leading name. They are at the forefront of innovation in India. Their solutions are made to not only automate systems but also optimize them. This ensures maximum efficiency and reliability.

Here is what the Messung BACD’s automation systems for HVAC and chiller plant system management include:

Intelligent Controllers: These can handle complex logic. They can adapt to changing building loads and environmental conditions.

Open Protocol Integration: This has compatibility with BACnet and Modbus, along with other protocols. This makes it easier to integrate with existing systems.

Real-time Monitoring and Dashboards: Facility managers can monitor energy usage with these. They can also look into equipment performance and environmental parameters.

Remote Access and Cloud Support: Messung BACD helps users control the chiller plants remotely, so the need for on-site personnel is reduced.

Predictive Maintenance Capabilities: Data logging and analytics help the system identify potential issues. These are caught before any breakdowns happen, so the equipment enjoys a longer lifespan.

Conclusion

Chiller plant management systems are important parts of the commercial infrastructure. They ensure comfort and protect sensitive environments. As buildings grow more complex, optimizing chiller performance is an absolute necessity. Messung BACD is a leading name in the world of chiller plant management systems. Their innovative and intelligent approach to chiller plant solutions helps your infrastructure remain remarkably efficient.

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The Messung XMP8-11 BDIO 08/06R Relay is a high-performance industrial relay designed for seamless automation and control. It ensures reliable switching, enhanced safety, and efficient operation in industrial environments. This relay is built for precision, offering 8 digital inputs and 6 relay outputs, making it ideal for automation systems. With robust construction and advanced technology, the Messung XMP8-11 BDIO 08/06R enhances machine performance and minimizes downtime. Whether used in manufacturing, process control, or industrial automation, it delivers optimal efficiency. Get Messung XMP8-11 BDIO 08/06R Relay at Auto2mation for reliable industrial solutions.

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Explore industrial automation in industry with Messung IAC and revolutionize your operations with cutting-edge technology. Our advanced automation solutions enhance productivity, reduce operational costs, and improve overall efficiency by integrating smart control systems, sensors, and IoT-enabled technologies. With real-time monitoring, precision control, and seamless process automation, industries can achieve higher output quality, minimal downtime, and optimized resource utilization. Messung IAC’s industrial automation solutions cater to various sectors, ensuring reliability, safety, and long-term sustainability. Upgrade your manufacturing and production processes with intelligent automation and experience a smarter, more efficient future with Messung IAC.

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Messung offers advanced automation systems for controlling in a distributed & redundant way, complex industrial processes, machines & production lines.

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Precision Redefined – PLC-Controlled Shock Absorber Testing Machines

Precision – a word that keeps on getting thrown around often in the world of engineering. However, when it comes to shock absorber testing, precision isn’t a luxury—it’s survival. Every curve, every jolt, every rebound of a shock absorber must be captured, tested, and analysed to microscopic exactness. Gone are the days when manual testing could keep up.

The role of shock absorbers in today’s high-speed automotive innovation and precision engineering is to provide safety, comfort, and performance protection. But how can we make sure that these absorbers meet the high standards required by modern vehicles? This is where PLC automation becomes a useful tool.

The old-fashioned testing methods, which were cumbersome, unreliable, and laborious, have been replaced by PLC-based automation systems. Imagine a testing line with the capacity to think, adapt and respond in real time. The precision of Programmable Logic Controllers (PLCs) is not solely a promise, but rather adherence to standardised protocols. 

How PLCs Enhance Shock Absorber Testing

There has been an evolution in the science of testing shock absorbers. Let’s understand how smart and compact PLCs can automate and optimise critical testing stages by providing consistency, control, and clarity. 

Centralised Control with High Reliability

A robust industrial PLC is the foundation of our testing machines. The real-time control systems embedded in our automation design enable seamless functioning of all sensor, actuator, and motorised components. 

Multiple sensors? Check. 

Complex test sequences? Seamlessly handled. 

From servo motion controllers managing high-speed vertical displacements to compact PLCs managing individual test stations, the formation is digital, deliberate, and dependable.

Real-Time Data Acquisition & Analysis

Here's where things get exciting. Tests on shock absorbers are more than just passing or failing. It's about quantifiable performance with our automation controllers: 

Damping force curves

Displacement maps

Velocity and resistance profiles. 

The data is gathered by high-resolution sensors and then processed through HMI with PLC controllers. The integration of this with databases is achieved through integrated PLC-based software, resulting in predictive maintenance and long-term performance insights

Feedback Loops for Adaptive Control

Ever wondered what would happen if the test differs? What would be the outcome? Well, with the use of real-time PLC communication protocols (like MODBUS and Ethernet/IP) and closed-loop control enable our systems to identify anomalies mid-test while enabling automatic correction.

Additionally, dynamic adjustment of actuator velocity in a system is possible when the response rate of the unit is slower than the tolerance. Or if temperatures spike? After a system shutdown, it sends an alert via the web server PLC and logs the fault. This requires more than just testing -- intelligent testing.

NX-ERA JET PLC System Architecture

Now let’s explore the engine room that fuels our innovation. The NX-ERA JET PLC, the foundation of our automated testing platform, undergoes a thorough architecture and connectivity analysis. 

Core Hardware Components

With its compact size, modular design, and future scalability, the NX-ERA JET PLC is a formidable beast. It houses: 

Simple servo systems designed for precise motion control

Energy-efficient motors can be powered by Variable Frequency Drives (VFDs)

HMI interfaces that enable the creation of visual dashboards and manual overrides

I/O modules for interfacing with third-party equipment. 

Its modular design makes it suitable for both high-volume testing environments and small-batch production lines that use Micro PLCs or Mini PLCs

Communication & Connectivity

Connectivity should be a fundamental aspect of the entire setup, not an extra one. 

Modbus PLC Interface is responsible for ensuring device-to-device communication

High-speed data relays are made possible with Ethernet-based controller systems

PLC with TCP/IP can be used for remote data logging and system control, as well as firmware updates

IoT-ready PLCs enable the integration of the testing machine with ERP, MES, and SCADA

Key Benefits of PLC-Controlled Testing Machines

Indeed, inefficient processes are not easily exploited in the fast-paced manufacturing industry. Your requirements include testing devices that don't blink even when pressured, systems that guarantee high quality, and technology that evolves as your business grows. Our PLC-based automation solutions are precisely in tune with that.

They offer:

Repeatability and Precision - One unit can be tested with ease and accuracy. But what about testing thousands with zero deviation? Our automation solutions that utilize PLCs accomplish this objective. You get: 

Identical test cycles

Calibrated control parameters

Automated calibration routines 

It implies improved quality control and enhanced audit accessibility.

High Throughput with Reliability - Traditional systems often require individuals to choose between speed and accuracy. Not here. The configurations of our NX-ERA JET PLC enable: 

Sub-second test cycles

Parallel station control

Integrated logic and safety layers 

All without compromising test integrity.

Reduced Manual Intervention - By utilizing HMI integration, and adaptive PLC programming, operators can not only monitor and but control:

Reduced human error

Faster changeovers

Safer work environment

Safety and Compliance – Safety is crucial for any industrial setup. With our smart PLCs, you can easily:

Emergency stop circuits

Real-time fault diagnostics

Layered safety logic

PLCs are designed to provide timely and effective alerts and shutdowns, complying with international standards such as ISO and CE. 

Adaptable and Future-Ready - Different testing may be required for tomorrow's shock absorber. Good news: you won’t need a new machine. 

Reprogram testing logic

Add new motion profiles

Update firmware via PLC with IoT

That’s the power of modular PLCs.

Whether you're chasing precision, throughput, or transformation, our PLC-controlled shock absorber testing machines deliver across the board. These benefits aren’t just technical specs—they’re business advantages, engineered to give you control, confidence, and a competitive edge.

Why Choose Messung’s Programmable Logic Controllers for Automation Solutions

Your choice of controller can determine your plant's success in a world propelled by data-driven decision-making, agility, and accuracy. We offer complete PLC-based automation solutions meant to grow with your demands rather than just supply PLCs. Our PLCs are not only intelligent but also necessary for the following reasons:   

Smart and Connected PLCs - Our smart PLCs dynamically optimise by adjusting to handle changes. Embedded intelligence enables them to learn from repeated tests, predict component failures, and optimize actuator profiles automatically. Moreover, our edge-computing enabled PLCs help for quicker decisions by lowering cloud dependence. 

HMI Integration for Better User Control - No more enigmatic command-line interfaces. With our smart PLCs, you get touchscreen HMIs, customised dashboards and real-time analytics displays. 

Compact and Versatile PLC (Programmable Logic Controller) Options - Squeezed on space? You can get the complete power of a typical controller, without worrying about the size, with our compact PLC, micro PLC, and mini PLC range. 

From intelligence that anticipates, to interfaces that simplify, to form factors that adapt—Messung’s PLC Programming range is designed not just to meet your automation goals, but to exceed them. Because when you choose Messung, you don’t just adopt automation; you embrace transformation.

Applications Beyond Shock Absorbers

Although shock absorber testing is where our PLC automation solutions show their power, that's just one section in our automation playbook. Beyond the same technology, fine-tuned for real-time control, precision, and adaptability, extends far. Messung's intelligent PLC solutions provide flexibility and value across a range of sectors, whether you are forming metal or transporting materials. 

Let's explore how our PLC Control Systems have a range much outside the damping zone: 

Motion Control Systems - Conveyor automation and actuator-driven systems all fall under our motion control solutions. Through synced servo motion controllers, we guarantee millisecond-level accuracy.

Machine Tool Controllers - Integrated with smart CNC tools, our machine tool controllers use feedback to adjust cutting speeds, minimise tool wear and even optimise material usage.

Advanced Automation – Through this end-to-end automation, sending raw material to finished parts, fully automated quality checks and centralized command via connected PLCs can easily become possible.

One shouldn't limit automation to just one purpose. Whether it is in high-speed assembly lines or precise machining at Messung, our PLC automation systems are flexible enough to meet the demands of many industries. Beyond shock absorbers, our solutions usher in intelligent manufacturing possibilities one motion at a time.

Conclusion

Accuracy is a standard, not only a specification. If you are still using obsolete testing configurations, it's time to change course. Designed to bring not just performance but also purpose to your production floor, Messung's PLC-controlled shock absorber testing equipment helps you to achieve this.   

Testing has to be quick, adaptable, and flawless, whether you are creating luxury cars or robust trucks. That is precisely what Messung's PLC control systems promise—and deliver. 

We do not just automate; we elevate, from servo-tight control to smart data acquisition, from seamless integration to Industry 4.0-based controllers.

At Messung, accuracy is not just redefined. It has changed everything. Hence, go for it. Redefine accuracy. One test at a time!

FAQs

What makes Messung’s PLC Control Systems ideal for shock absorber testing?

Messung’s PLCs (Programmable Logic Controller) offer centralised control, real-time data capture, adaptive feedback loops, and ensure peak accuracy and speed.

Can Messung’s PLC Programming integrate with existing equipment?

Yes. With protocols like MODBUS, TCP/IP, and Ethernet-based controllers, our PLCs are designed for easy retrofitting and compatibility.

How do PLC Control Systems improve the testing process?

PLCs provide real-time emergency stop functionality, error detection, and ensure the equipment runs within safe operational parameters.

Do you offer remote access features?

Absolutely. With web server PLC (Programmable Logic Controller) capabilities and HMI with PLC controllers, you can monitor and manage testing remotely.

Is your PLC solution scalable?

Yes. With modular PLCs and IoT-ready systems, you can scale your setup to match your growth.

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Think All Chiller Controls Are the Same? Think Again with Messung

Think all chiller control systems offer the same performance? Think again. Messung BACD delivers advanced chiller control solutions that go beyond basic automation. With intelligent features, real-time monitoring, and energy optimization, our system ensures superior efficiency and reliability for HVAC applications. Discover how Messung BACD is redefining climate control in commercial and industrial spaces. Experience smarter, more sustainable operations with a control system that truly makes a difference.

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https://www.messungautomation.co.in/how-does-programmable-logic-controller-plc-work/

Enhance industrial automation with Messung IAC’s advanced Programmable Logic Controller (PLC) solutions. Designed for precision, efficiency, and reliability, our PLCs ensure seamless control of industrial processes, reducing downtime and optimizing productivity. With real-time monitoring, intelligent programming, and robust performance, our PLC systems are ideal for various industries, including manufacturing, energy, and infrastructure. Messung IAC’s automation solutions integrate cutting-edge technology to deliver superior process control, ensuring safety, consistency, and cost-effectiveness. Upgrade to smart automation with our industry-leading PLC solutions and experience the future of industrial control. Discover innovation with Messung IAC today!

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Enhancing AHU Performance with PLC-Based Control Systems

Imagine a world where your building breathes in oxygen. Where comfort meets air quality, and where energy is saved. It is the world where AHUs and PLC control systems are the starting point of everything in the domain of Energy management systems. 

These AHU controllers (Air Handling Units) are the primary components of any new HVAC system. They serve as the lungs. But to make those lungs breathe better, smarter, and cleaner, you need a brain—enter the Programmable Logic Controllers (PLC).

We at Messung Industrial Automation are not just manufacturing PLC automation systems. We engineer intelligence. Smart PLC control is our ambition, and we aim to revolutionize the way AHU controllers operate, using a range of technologies, including Modbus, MQTT, compact PLCs, or IOT-enabled PLC. 

What is a PLC-Based AHU Control System?

A PLC-based AHU control system is the ultimate HVAC master conductor. The flow, cooling, heating, and energy consumption of air are all controlled by real-time logic and precision through automation controllers. 

Decision-making is the primary responsibility of a IoT enabled PLC (programmable logic controller), not just following instructions. Your AHU is designed to respond to data, adjust to changing surroundings, and function like a finely tuned machine with the help of intelligent controllers. 

Whether it’s a mini PLC for a compact setup or a modular PLC for a multi-zone building, this IEC 61131-3 standard controller is the heartbeat of your air management system.

Core Functions of PLC Automation in AHU Controllers Applications

Sensor Integration

Temperature, humidity, CO2, and differential pressure are all sensors that your AHU controllers are equipped with. When it comes to Energy management systems, PLC control systems are necessary for reading, interpreting, and operating raw data. 

Our intelligent PLCs work together with sensors to capture every detail of your indoor environment. 

Data Analysis & Decision Making

After submitting the data, the PLC Automation magic begins. Our IEC 61131 based PLCs utilize advanced logic and maintain monitoring of variables such as: 

Room occupancy

Outdoor air quality

Return air temperature

The intelligence in this scenario is not confined to automation alone it expands to the action of the PLC Control Systems. 

Control Actions via Actuators

Now let's talk about the muscle of the operation. By utilizing PLC and Modbus TCP/IP, your automation controllers can dynamically control VFDs (Variable Frequency Drives) to regulate fan speeds while minimizing energy usage. 

Actuated Dampers

Want zoned cooling in your building? Each damper is given precise guidance on when and where it should be opened or closed by our compact PLC, down to the second. 

Valves

Our PLC automation system manages both hot and chilled water circuits, ensuring thermal comfort with accuracy. 

Humidifiers & Dehumidifiers

System Overview: The NX-ERA JET Advantage

NX-ERA JET PLC is a digital command centre that is agile, adaptive, and always on alert as the AHU controllers. We have developed an intelligent and IEC 61131-3 standard PLC Control Systems that combine advanced logic, seamless connectivity, and flexible scalability. The NX-ERA JET is the key to ensuring that every component of your AHU system, including sensors and actuators, operates in perfect harmony. 

Features of this IoT enabled PLC at a Glance

Modular PLC architecture is flexible and can be easily scaled for multi-zone management in large or changing infrastructure

The utilization of PLC with TCP/IP facilitates fast and secure communication between devices, including devices connected to remote systems

The integration of MODBUS RTU, Modbus TCP, and MQTT with BMS, SCADA, or cloud-based IoT platforms is facilitated by the native support provided by these protocols. 

An integrated HMI that provides real-time, intuitive monitoring, diagnostics, and manual overrides.

Benefits of IoT enabled PLC for AHUs

In modern air handling, the focus isn’t just on moving air but moving it forward. Why? Integrating PLC control systems into AHUs can offer a transformative advantage in performance, sustainability, and adaptability for buildings. We should examine why PLC automation is the primary driving force behind intelligent HVAC solutions. 

Improved Energy Efficiency 

The value of energy is high, and PLC for energy systems with IEC 61131-3 standards optimizes every kilowatt. We can use our IoT enabled PLCs to save energy - up to 30% a time with intelligently controlled fan speeds, valve positions and damper angles that are real-time. Measurable reductions through these intelligent controllers help to reduce operational costs and greener footprints are not just numbers. 

High Precision Control

AHU controllers equate performance with precision. Why? Our IEC 61131-3 compliant PLCs provide precise control over airflow, temperature and humidity. The result? Consistent comfort, efficient performance and strict environmental regulations. 

Advanced Diagnostics

The use of intelligent PLCs with IoT systems means that problems can be prevented rather than delayed. With real-time monitoring and fault detection, teams can receive predictive maintenance insights to minimize downtime and maximize up time. 

Scalability and Modularity

Our modular PLCs are designed to accommodate the growth of your building, offering compact systems and multi-zone installations. Do you require an immediate upgrade or expansion? These intelligent controllers can scale without complexity. 

BMS Integration

Our PLC Control Systems with IEC 61131-3 standard integrates seamlessly with Building Management Systems, creating one intelligent ecosystem. Whether it’s HVAC, lighting, fire alarms, or access control—everything talks to everything for smoother operations.

In a world where data and efficiency are the primary drivers of change, PLC-controlled AHU controllers provide more than just automation; they also offer confidence. Our IoT enabled PLCs enable buildings to thrive rather than just functioning.

Intelligent PLC Control Systems for Smart Buildings

HMI with PLC Controllers - An HMI with PLC controller enables the observation of invisible areas. The entire package, including fan speed and filter life, is conveniently located at your fingertips. 

MQTT based PLC and IoT Systems - The integration of IoT enabled PLC and MQTT support enables your AHU to communicate with the cloud, apps, and analytics platforms, simplifying the process of achieving predictive control and remote access. 

Real-World Applications

Through PLC-based AHU control systems, we at Messung are changing the possibilities of environments from sterile labs to busy malls. With precision, adaptability, and unparalleled reliability, our intelligent automation controllers tackle the challenges associated with every application. 

Pharma Cleanrooms - The precision of pharmaceutical products is essential in their application. The strict GMP standards are adhered to by our PLC control systems, which involve managing temperature, humidity, pressure differentials. The result? Zones that are sterile, upholding drug integrity and safety.

Commercial Buildings - Employee comfort drives efficiency. Our HVAC automation enables seamless climate management of all floors and departments. By utilizing intelligent design, efficient air circulation, and real-time monitoring, our IoT enabled PLCs enhance the productivity and satisfaction of customers in spaces. 

Data Centers - Servers demand a stable climate 24/7. Even minor temperature fluctuations can compromise data. Our intelligent PLC Control Systems with IEC 61131-3 standard ensure uninterrupted cooling performance, reducing thermal risk and operational downtime.

Energy-Efficient Manufacturing - Today's manufacturers must strike a balance between sustainability and production. Without compromising comfort or compliance, our PLCs maximize AHU performance to reduce energy footprints, reduce emissions, and guarantee stable internal environments.   

Wherever there's air to manage and performance to perfect, our Compact PLCs lead the way with intelligent control.  

Messung’s Expertise in HVAC Automation

We at Messung lead the way in HVAC automation innovation for organizing smart air movement. Our legacy is created on trust, performance, and innovative control systems that transform indoor environments, not only on technology

Why Choose Messung PLC Automation?

We design smart automation systems rather than only selling PLC Control Systems. With more than four decades of engineering expertise, our PLCs are the favoured option of architects, MEP consultants, HVAC contractors, and facility managers across India and globally. Our internal R&D, field-tested dependability, and quick support system turn us into a progress partner rather than just a supplier.   

Built on IEC 61131-3 Standard

To ensure every Messung programmable logic controller is consistent, dependable, and compatible with worldwide systems—today and tomorrow — our automation controllers follow this internationally recognized IEC 61131-3 standard. 

Flexible Form Factors

Whether you are managing many air zones throughout a smart high-rise or automating a small rooftop AHU, our compact and modular PLCs meet every architectural and functional requirement.   

Comfort, control, and conservation are not optional but rather vital in the quickly changing realm of smart infrastructure of today. Furthermore, realizing this potent triad calls for smart, adaptive control rather than just automation. That is what Messung's PLC-based AHU systems precisely provide. Our programmable logic controllers redefine air handling performance for buildings of all sizes with real-time responsiveness, easy BMS integration, IoT readiness, and IEC 61131-3 standard. Our intelligent controllers offer precision, dependability, and next-generation energy efficiency from sterile zones to skyscrapers. Should excellence be your goal, our IoT enabled PLC guarantees you lead rather than merely follow.  Why settle for fundamentals when you may automate brilliance with our smart automation controllers?   

FAQs

What makes a PLC suitable for AHU control?

Real-time processing, sensor compatibility, actuator control, and smooth BMS integration define good automation controllers. Messung's smart PLCs with IoT systems check every box

Can a modular PLC (Programmable logic controllers) handle multiple AHU zones?

Absolutely. Modular PLCs like Messung’s NX-ERA JET are great for big buildings since they can span levels and zones. 

How does Messung's IoT enabled PLC enhance building performance?

Connecting to cloud systems and providing remote access help our IoT enabled PLCs to maximize energy efficiency and real-time maintenance cycles.   

Why is Messung’s NX-ERA JET the ideal, affordable PLC choice for midscale operations compared to traditional compact or mini PLCs?

Messung’s NX-ERA JET offers advanced performance at an affordable price, making it perfect for midscale operations. It outperforms mini PLCs with better speed, scalability, and flexibility, without breaking the budget.

Are MQTT based Programmable logic controllers better than traditional protocols?

MQTT-based PLCs offer faster, lighter, and more effective communication than conventional systems like MODBUS RTU for remote and IoT-intensive applications.

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https://messungbacd.com/energy-management-system.php

Advanced Building Energy Management System | Messung BACD

Messung BACD offers intelligent Building Energy Management Systems (BEMS) designed to optimize energy usage, reduce costs, and enhance operational efficiency. Our advanced automation solutions enable real-time monitoring, control, and analysis of energy consumption across facilities. Ideal for commercial and industrial buildings, Messung’s BEMS supports sustainability goals and ensures regulatory compliance. Experience smarter energy management with scalable, reliable, and future-ready systems customized to your needs. Discover how Messung BACD transforms buildings into energy-efficient spaces.

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Introducing XMPS-2000: Messung's Advanced PLC Programming Software

Messung - Industrial Automation & Controls

Next generation Industrial Automation & Control Solutions for complex industrial processes, machines & production lines.

Messung Industrial Automation is proud to unveil the XMPS-2000 software, a powerful and intuitive Windows-based utility designed to enhance the programming experience for the XMPRO-10 PLC series. With a focus on user-friendly interfaces and robust functionalities, XMPS-2000 is set to redefine efficiency in industrial automation.

Key Features of XMPS-2000:

·         User-Friendly Environment: 

    The software offers an intuitive interface, ensuring a seamless experience with various software tools.

·         Programming Flexibility: 

    XMPS-2000 supports the standard Ladder programming language, making it compatible with a wide range of applications. The software complies with IEC 61131-3 Standards.

·         Online Diagnostics: 

     Real-time diagnostics functionality allows users to monitor runtime status effectively.

Advanced Programming Capabilities:

·         Hardware Configuration: 

     Facilitates CPU and I/O modules hardware configuration, simplifying system setup.

·         Logic Blocks: 

     Enables the creation of subroutines that can be called within the main block, promoting organized and modular programming.

·         Monitor Table: 

    Allows for user-defined tags, communication variables, and a watch window for real-time monitoring of discrete and analog I/Os.

·         Online Monitoring: 

     Supports real-time monitoring of ladder programs and generates cross-references for efficient debugging.

·         Force Value Functionality: 

    Permits value forcing during program testing, aiding in thorough validation processes.

·         User Library: 

     Offers the creation of user-defined function blocks for customized tasks or specific applications, enhancing reusability.

System Configuration Management:

·         Comprehensive Selection: 

     Allows selection of XMPRO CPU, local and remote I/O expansion modules, and displays total I/O count.

·         Communication Parameterization: 

     Facilitates communication ports parameterization, supporting protocols like MODBUS TCP and RTU.

Hardware Selection Visualization:

·         Detailed Display: 

    Provides visualization of hardware configurations for selected CPUs and I/O modules, with direct parameter configuration and viewing.

I/O Configuration:

·         Assignment Flexibility: 

    Supports I/O assignment for onboard, expansion, and remote I/O modules, with mode selection for analog inputs and outputs.

·         System-Generated Addresses:

     Automatically generates I/O addresses, simplifying the configuration process.

Program Structure:

·         Efficient Tools: 

    Features a toolbar with shortcuts to ladder elements and instructions, a project management window for file creation, and a program edit window in standard ladder format.

·         Compiler and Monitoring: 

     Includes a compiler window for error display, an online monitor window for real-time project monitoring, and a watch window for user-selected variables.

The XMPS-2000 software exemplifies Messung's commitment to delivering innovative and efficient solutions in industrial automation. By integrating advanced features with a user-centric design, XMPS-2000 empowers engineers and technicians to achieve higher productivity and precision in their automation projects.

For more information and to experience the capabilities of XMPS-2000, contact Messung Industrial Automation.

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NX-ERA unleashes the power of IIoT with MQTT Interface

The Industrial Internet of Things (IIoT) - sometimes called Industry 4.0 - is radically changing how businesses, especially industrial companies, operate.

 Definition:

Let’s begin with a short IIoT definition: The Industrial Internet of Things (IIoT) refers to the vast number of machines and devices - or ‘things’ - a business uses that are now connected to the Internet. Protecting this critical operational data, secure IIoT forms a closed, private Internet network where the devices can communicate and share data with other people, systems, and things. This data can be used to improve existing work practices and business processes as well as creating entirely new ways of doing things.

 Benefits of IIoT:

As IIoT devices become smaller, cheaper and smarter, they can be applied almost everywhere. The data they create can be turned into actionable insight that delivers incredible business benefits including:

Improved operational efficiency

Industrial IoT software allows you to create environments of connected assets that bring a wide range of operational efficiency benefits. Sensors located in production systems, assembly lines, warehouses and vehicles produce data that helps managers monitor exactly how an asset is performing and address issues before they arise.

Increased productivity

Industrial IoT solutions provide real-time information on the performance of equipment and people to help streamline and improve business processes and workflows.

Cost reduction

Deploying IIoT offers large cost saving benefits for organizations. For example,  industrial IoT devices can save dramatically on energy bills - by as much as 70% on lighting and 30% on airconditioning, according to some estimates.

Enhanced customer experience

By placing industrial IoT sensors within products, manufacturers are able to capture and analyze data on how customers actually use their products - enabling them to improve future product upgrades and releases.

Reduced waste

Inventory management is one of the most important benefits of IIoT software. By attaching IIoT devices to products, warehouses and vehicles you can make the entire supply chain process more effective, reducing the need for excess inventory and the potential for stock-outs.

Many organizations have been attracted by the benefits of industrial internet of things but realizing those benefits is not straightforward. There are many industrial IoT challenges to overcome before an organization can institute a successful IIoT program. These include:

Industrial IoT Security

·         Security is one the biggest challenges for IIoT adoption. Many devices are collecting extremely sensitive data but, in many cases, the devices have been designed with little thought to security. Industrial IoT security must ensure that the identity of every person, system and thing on the network is properly managed and detected.

Data Privacy

·         As more and more devices are connected to the Internet, concerns surrounding how personal and sensitive data are captured, transmitted and stored also grow. The value of IIoT lies in the ability to access, integrate, and analyze this data while maintaining data privacy.

Industrial IoT Standards

·         Standards lie at the heart of the development and adoption of IIoT. Today, there are many IIoT standards but little standardization. For example, IIoT devices use a variety of methods to connect and share data, including LTE, LP-WAN, wi-fi, Bluetooth, satellite and even Ethernet when connected directly to a network.

Data Management

·         Handling the volume and velocity of data being created by industrial IoT devices is a significant challenge for every organization. All this IIoT data must be collected, stored and analyzed before it can be turned into actionable insight that can drive improved decision-making.

Deployment Models

·         According to PTC, 62% of IIoT deployments are on-premise, while 38% are in the cloud. The vast amounts of IIoT data being created places greater pressure on delivering flexible and scalable capacity. For industrial IoT, a cloud deployment offers performance and security gains over on-premise solutions. Hybrid industrial IoT cloud deployment - splitting processing between internal systems and the cloud - is a fast-growing deployment model for many businesses.

Range of IIoT Devices

·         IIoT has many different components and there are many different types of industrial IoT devices. Typically, industrial IoT device examples include sensors, actuators, tags, beacons and receivers. When creating an IIoT network, all these devices have to be effectively and securely integrated to derive the full value of your IIoT investments.

IIoT Protocol:

Of the many different protocols Message Queue Telemetry Transport (MQTT) complements all the necessities of IoT. With a view to meet the Industry 4.0 demands, Messung now offers NX-ERA, the complete industrial automation solution to connect your business to IoT universe. All of our NX-ERA products now support MQTT.

When updating the firmware of the PLC to the latest version and using MasterTool IEC XE version 3.20, all the NX-ERA PLCs could make your business closer to Industry 4.0.

Why MQTT?

 It is a lightweight message protocol that is based on subscription-publishing model and requires low bandwidth. E.g.: Facebook uses MQTT for its messenger product on mobile platform, to ensure usage of this application is minimized.

·         This model follows/defines two entities in the network: the broker (also called server) and the clients.

·         Using our MasterTool programmer, the user will be able to transform our PLC into a client, thereby allowing from a simple TCP / IP connection to a secure connection based on TLS certificates.

MQTT is a high-level architecture and consists of two main parts (Broker & Clients)

 Broker:

·         As can be seen, this protocol does not require synchronization between the parties involved, as the broker is responsible for ensuring the delivery of published messages.

·         So, broker helps to sort the information and better manage the messages.

·         Types of brokers available are Eclipse IoT Mosquito, Active MQ, Hive MQ etc.

Clients:

·         Clients are any devices (PLC in our case) which interact with broker; either publishing messages or subscribing to a topic.

·         Topics are the routes where messages are published within a broker.

        When PLC publishes message to the broker; and broker forwards this message to subscribers avoiding point-to-point connections between subscribers and publishers.

·         When broker (server) publishes any message, then PLC (client) acts as a subscriber.

·         MQTT supports TLS (Transport Security Level) for secure connection between client & server. Communication between client and server is established via TCP connection or an encrypted TLS connection for secure messages.

 Web Service Tools

·         Any web service tool could be used as a programming platform for intuitive and straightforward integration between smart devices, PLCs and brokers. Node-Red is an example of the web server tool.

·         If we write or publish a message from Node-Red, this published message will be received by broker first. If PLC is subscribed to this message under any topic, then it will receive the message from the broker.

·         Thus, it is possible to communicate with different cloud platforms, such as Node-RED®, where it is possible to create supervision diagrams for an entire system, including different devices.

 SCREEN DISPLAY ON MOBILE/TERMINAL/TABLET through CLOUD PLATFORM/LOCAL SERVER  

 TYPICAL ARCHITECTURE

STUDY

 Our customer is an Automotive Ancillary Manufacturing company having a huge installed base of PLCs (of different make) in their premises being utilized for varied applications including Robotic Cells.

 Customer Requirement

Application: Robot Line Welding Machine

The customer wanted his PRODUCTION data and some critical alarms to be monitored on Web Visualisation tool and to collect the data centrally in a local Server. Also to be energy efficient, the customer wanted to monitor energy consumed at each stage of the production line.

 Proposed Solution:

Since the existing PLC does not support Industry 4.0 compatibility, Messung suggested a cost effective solution to retrofit the PLC with latest NX-ERA XPRESS PLC which has integrated multiple protocol communication including MQTT & OPC UA protocols.

To take care of energy management control system, energy meters were installed with Modbus RTU communication facility. The NX-ERA XPRESS PLC gathered the data from the energy meters on integrated MODBUS Protocol (inbuilt RS485 port). Moreover the data was compiled and sent to the Customer Server.

The application was developed, panel rewired and monitored within an hour. What's more, this task was accomplished during the break, so it helped to reduce machine downtime.

The data was taken on TCP/IP port to the Customer Server on MQTT with broker running on the same.

 Production Management Solution:

Monitoring & Data Recording

      CONCLUSION

 Messung NX-ERA PLCs for Industrial Automation have opened new doors to ever increasing demands for Internet of Things by introducing MQTT, where the users can operate, make analysis and even save on their existing sensors, devices or even machines.

With Messung's smart factory automation & control solutions, users can check, monitor and even control some of the critical functionalities of any machine in the plant at their fingertips on their interactive devices based on operating systems like MAC OS, Windows, IOS or Androids.

As proven industrial automation system integrators and leading PLC supplier in India, Messung has in-depth understanding of industrial machinery, production processes and practical implementation of technology, complemented by a strong team of experienced engineers with tried and tested execution methodology.

A pioneering industrial automation & control systems supplier and provider of machine automation & control solutions for four decades, you can trust Messung's cutting-edge industrial automation & control solutions with IIoT to transform operations and efficiencies across the shop floor.