Blenders, PLCs, motion controllers, meters — the hardware that keeps a plant running rarely gives its data up easily. Reverse-engineering that data and putting it on a screen operators actually use is what we do. Same polish standard as everything else we ship, pointed at real machinery.
We don't ask a plant to change its hardware. We meet the equipment where it is — and where a bus is proprietary, we reverse-engineer it.
Maguire gravimetric weigh-batch blenders are workhorses — but the good data lives behind a proprietary protocol, and the controller only shows it two lines at a time on a keypad LCD. We pull it out. Real consumption, real batch weights, real cost-per-shift — off the actual hardware, onto a dashboard, and into your ERP. No guessing, no "the vendor says it can't be done."
A Maguire's Modbus TCP port isn't a normal Modbus device — it's a wrapper around Maguire's own MLAN protocol. Point standard register tools at it and you get noise. We mapped the real path: MLAN command codes (Get Totals, Cycle Weight, Batch Info) tunneled inside the Modbus packets, plus a careful parse of the keypad LCD buffer for the fields the protocol won't hand you directly. The result is honest numbers — and where the firmware genuinely can't report a value live, we label it a snapshot with a timestamp instead of faking it.
Glanceable per-machine screens: recipe, component setpoints, live/last-reported weight, batch state. Runs in demo mode or live mode, so operators can train on it before it ever touches the real controller.
Per-hopper material cost computed on real consumption deltas — mid-shift price changes costed correctly, before and after. Editable bill-of-materials with supplier and price per component.
Clean 8-hour shift rollups for accounting and purchasing: day / month / year filters, per-drop batch logging with gap detection (a missed drop is shown, never fabricated), one-click PDF, Excel, and CSV.
Decodes what the controller is actually doing — component types, setpoints, batch targets — and flags the states that trip crews up. Built from the register / MLAN behavior we reverse-engineered.
Material consumption pushed into eIQ the way eIQ actually wants it: BOM-driven backflush against a work order. Every inbound method covered — folder-watch CSV/XML, WebAPI with token auth, FTPS, live Modbus/OPC UA/MQTT, MTConnect. One config file is the only thing your IT ever edits.
Field setup without the vendor on the phone: a preflight validator that catches the silent killers (missing unit-of-measure factors, empty part-number crosswalks) before go-live, plus the controller-side sequence to actually enable the data feed. We've done the fussy parts already.
We build private, plant-dedicated troubleshooting portals — one home screen, every machine on the floor behind it. Pick a line and you get its troubleshooter and its PLC configuration side by side, the same shape whether the line runs a WAGO PLC or a Yaskawa one. A technician's tool, not a brochure — deployed for a single plant, not sold off a shelf.
For complex motion machines we go deeper: fault search, a full I/O map, a live PLC monitor over Modbus, the electrical schematic on-screen, and a knowledge base built straight from the machine's ladder program. We've found a marginal braking resistor by reading the run-enable edge and brake handshake — not just reciting an alarm number.
Letter-landscape drawings with a proper zone border, title block, BOM, and notes — drawn with standard JIC ladder symbols (N.O./N.C. contacts, pushbuttons, coils, beacons, PSU boxes, wire hops). Give us the control scheme; we hand back a client-ready print package with matching operation and sensor guides.
Inherited a machine with 1,000+ steps of uncommented ladder? We monitor the live logic while operating the machine, decode each bit / timer / register, and round-trip the labels back into the project's device comments — so your maintenance team inherits a documented program.
A local semantic search engine across ~1,000 plant PDFs — PLCs, drives, heat controllers, meters. Ask in plain English, get the exact manual and page number back. Runs entirely on-prem; nothing leaves the building.
We don't hand you a folder of scripts. Our industrial software ships as a real Windows installer — packaged, professionally installed, and supported, with the same productization discipline as any commercial vendor and the integration options kept free and open.
The same engineering that goes into our dashboards goes into training. We're building interactive electrical training — live, animated schematics driven by a real circuit solver, not slideshow pictures — through a baby-steps-to-advanced curriculum built for new technicians who need to understand the cabinet, not just memorize it. A few tidbits from the bench:
Every diagram runs on a real circuit solver. Press START and the coil energizes, contacts flip, the seal-in latches, and current lights up the wire path. A built-in virtual multimeter reads true electrical potentials off the simulated circuit — you probe the drawing the way you'd probe the bench.
A 30-module track that starts at "electricity is just water in pipes" and works through contacts and coils, seal-in latches, 3-wire start/stop, timer relays, and plant voltage hierarchies — each module with its own knowledge check — up to a capstone: diagnose a dead motor start/stop station.
Broken circuits with names like "Motor Won't STOP — The Runaway" and "Which Light Is Lying?" No multiple choice: you get a misbehaving circuit and a meter, and you find the fault the way a technician does — systematically, one measurement at a time.
Lessons draw with the same JIC ladder symbols as our electrical print generation — N.O./N.C. contacts, coils, overloads, pilot lights — so what a learner reads on screen matches the drawing hanging in the panel shop.
Every plant is different. Tell us what you run and what you need to see — we'll talk through the cleanest way to get there, from a single machine to the whole floor.
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