The mechanics still have value.
The controls should not condemn the line.

Keep what remains useful. Rebuild what makes operation fragile.

The mechanical base was retained while the control system was rebuilt. The decision links the value of the equipment to the risks of keeping an architecture that is difficult to support.

A complete control rebuild, across the whole line.

The original solution combined DOS software with proprietary logic and I/O boards. The logic boards had failed beyond repair, leaving the client unable to produce. The work involved reconstructing operating rules, coordinating movements and making stops understandable. The client had commissioned an earlier audit; OMNIATEC supplemented that initial understanding with on-site observations, interface checks and trials.

Timber does not follow a standard sequence.

Board lengths, geometry and defects vary. A board can rub, jam or split at a crack. One expected offcut can become several fragments, passing sensors separately or only partially.

The challenge is to turn that variability into reliable control decisions. Physical observations must be matched to recorded signals to distinguish a mechanical blockage, an unexpected detection and a control inconsistency.

On the shop floor, a stop is a fact to explain. The correction comes afterwards.

Available hardware. Software engineered within its resources.

The WAGO PFC200 G2 was selected because it was immediately available when equipment was ordered. Its computing resources shaped the software architecture. Some solutions had to be reworked because they were too demanding. The requirement was a program that remained efficient to execute, understandable and maintainable.

Give machine control priority.

Computational work varies with board length, defects and cutting options. Decisions must adapt to the material while the work performed by each processing step remains bounded. Machine movements and relevant measurements take priority; data handling and display updates are organised separately.

Follow the board all the way to the correct destination.

Movement alone is not enough. The measured material, cutting plan, actual position and destination of each piece must remain consistent.

Keep developing the controls amid real operating conditions.

Diagnostics and changes continued during degraded operation, with workshop noise, variable timber, mechanical disturbances, false positives and operator resets. Each stop required the useful facts to be recovered before another attempt obscured them. Operating practices also had to change: restart conditions, fault handling and workarounds inherited from the previous equipment were reviewed with operators.

Regain control of a critical asset.

OMNIATEC connects the mechanical, electrical, controls and process aspects of the problem. The approach is to establish what is known, prioritise production-critical functions and proceed through verifiable changes. Documentation and handover develop alongside the solution, so the result can be understood and maintained by the teams.