Escape Control was founded to provide focused PLC programming and industrial automation support, backed
by more than 20 years of professional experience working with PLC-controlled machines and processes.
I take on focused automation projects with attention to reliability and detail, one project at a time.
My work focuses on PLC programming and industrial automation, with Siemens as my primary current
platform. My earlier experience also includes Rockwell (Allen-Bradley), Mitsubishi, and Schneider
systems.
I apply established control programming principles to each project, adapting the approach to the
equipment, platform, and requirements involved.
Core expertise
Custom PLC programming for industrial machines and production lines
Development in Ladder Logic, Structured Text, Structured Control Language, and Function Block
Diagrams
HMI/SCADA work primarily in Siemens environments such as WinCC, with earlier familiarity with
other industrial packages including FactoryTalk and Ignition
Control software structured for maintainability, with clear documentation as agreed
Remote consulting and troubleshooting where suitable access is available
The focus is practical problem-solving: clear logic, maintainable software, and systems that stay
understandable after handover.
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Services
PLC Programming & Configuration
When a machine or line needs new behaviour, clearer sequencing, or more maintainable logic, I
develop or modify PLC software to match the agreed operating requirements.
Modifications to existing controls and defined new control functions
Siemens-focused delivery, with earlier multi-platform experience
On-site or remote work, as agreed for the project
HMI & SCADA Development
When operators need clearer screens, operating modes, alarms, or status information, I implement
or update HMI and related visualisation so day-to-day control matches the PLC behaviour.
Operator screens, mode selection, and status messaging
Alarm and event presentation where included in scope
Changes coordinated with the underlying PLC logic
Automation Consulting
When the control approach is unclear — for example, when assessing retrofit options or planning a
change — I help assess the existing automation and recommend a practical way forward.
Review of the current PLC/HMI setup and relevant constraints
Recommendations on scope and approach before implementation
Practical guidance when the next step is not yet clear
Troubleshooting & Support
When a system behaves unexpectedly or a fault is difficult to identify in the control software, I
help diagnose the issue and work towards restoring stable operation within the agreed access and
safety boundaries.
Fault-finding in PLC/HMI behaviour
Remote support where suitable remote access is available
On-site support where agreed and appropriate
Case Studies
Flexible Production Upgrade for Control Arm Welding
A PLC and HMI upgrade on two lower control arm welding lines added a
production mode so left-hand, right-hand, or paired parts could be produced independently —
addressing inventory imbalance after rejected parts and improving production flexibility.
Read more
The welding lines were originally configured to produce left-hand and right-hand lower
control arms as matched pairs. When a fault resulted in a rejected part on one side, an
inventory imbalance was created between left-hand and right-hand components. These
unmatched parts could not immediately be used to fulfill production requirements and
often had to be stored until the inventory balance was restored.
The project included extensive PLC programming modifications and the development of new
material-handling routines across robotic cells and fixture stations. Updates were
implemented throughout the production process, including input, marking, milling,
welding, and exit stations, ensuring reliable single-side production while maintaining
existing line functionality.
HMI enhancements included production mode selection, status indication, and operator
messaging to support the new operating modes.
Outcomes described for this work
Improved management of left/right inventory imbalances
Increased manufacturing flexibility
Reduced work-in-progress storage requirements
Enhanced operator visibility and control
Integration with existing automation systems
Selective Nut Welding Rework Mode Upgrade
A PLC and HMI upgrade introduced a Selective Nut Welding Rework Mode,
allowing parts with missing weld nuts to be reintroduced for targeted repair. The system
combines vision inspection, operator-guided selection, and robotic welding with full
traceability, reducing scrap without adding a new workstation.
Read more
The upgraded system combines vision inspection, operator-guided nut selection,
robot-controlled welding, and full traceability tracking through a virtual production
code. Automated verification confirms the presence of all required nuts before the part
exits the cell, while intelligent mode management supports efficient and reliable
production operation.
The work covered PLC/HMI changes together with vision-guided selection, robotic welding
integration, and traceability in the rework flow.
Welding Cell Upgrade & IO-Link Integration
Rather than purchasing a new workstation, this project extended an
existing 4-position rotary table with two additional interchangeable welding jigs. PLC and
HMI updates added support for modern IO-Link tooling, improving diagnostics, maintainability,
and scalability while reusing existing equipment.
Read more
The project involved PLC and HMI software modifications to accommodate new tooling
equipped with modern IO-Link technology, including dynamic tool detection and flexible I/O
mapping. The integration of IO-Link-capable industrial sensors and pneumatic valve
components improved diagnostics, maintainability, and future scalability.
Contact
If you have a PLC or industrial automation need, email a short description of the
request.
Useful details to include:
What the machine or system does, and what you want to change or fix
The PLC/HMI platform, if known (for example, Siemens)
Whether the work is expected on-site, remote, or either
The location and any timing constraints
Based in Hungary, I work with clients internationally, providing remote
automation engineering support and travelling worldwide for on-site project work as required.
