Automation, controls & functional safety
InnovaDrive diagnoses, modifies and verifies the control, communication, motion and safety systems that determine whether a test bench can operate reliably, repeatably and safely.
A failed sequence may originate in an operator command, a hidden PLC permissive, a safety condition, a network dropout, a drive state or a missing feedback signal.
Automatic sequence stops without a clear cause
PLC permissive remains false
Safety system resets but operation stays blocked
Drive is ready locally but cannot be enabled
PROFINET, PROFIBUS or CAN communication is unstable
Manual procedures need structured automation
Trace the complete command and feedback chain
Separate the symptom from the actual cause
Implement controlled and documented changes
Verify safe and repeatable operation
The intervention covers the automation layers that control machine state, movement, safety, communication and test execution.
PLC & sequence logic
- Siemens S7 diagnostics
- Operating states and permissives
- Manual and automatic modes
- Sequence steps and transitions
- Alarm and fault handling
HMI & operator interfaces
- Command and status visibility
- Alarm text and diagnostic feedback
- Manual controls and mode selection
- Parameter and setpoint handling
- Operator guidance and restart
Industrial communication
- PROFINET and PROFIBUS
- CAN and CAN FD
- Device-state diagnostics
- Signal timing and availability
- Communication configuration
Drives & motion control
- Bosch Rexroth IndraDrive
- Enable chains and control words
- Parameter and fault-state review
- Speed, torque and position commands
- Motor and actuator feedback
Functional safety systems
- Pilz safety relays
- Schmersal interlocks
- E-stop and reset circuits
- Gate and access monitoring
- Safe operating modes
Signals, sensors & DAQ
- Digital and analogue I/O
- Scaling and engineering units
- Signal plausibility
- Measurement-system exchange
- CANape and ETAS integration
Troubleshooting does not stop at the first visible alarm; the investigation traces the requested action through every control, safety and feedback layer.
Operator command
Requested action
HMI request
Command accepted
PLC logic
Sequence and permissives
Safety status
Safe conditions
Network exchange
Device communication
Drive or output
Control command
Physical response
Motion or process action
Feedback signal
Actual system state
Sequence progression
Next operating step
Commands are traceable
Operator requests can be followed through logic, outputs and physical response.
Permissives are explainable
Blocking and enabling conditions are visible and technically understood.
Safety states are consistent
Safety devices, relays, PLC status and machine response align.
Networks remain stable
Required devices and signals remain available during tested operation.
Automatic sequences progress reliably
Expected transitions, interruptions and restart paths are demonstrated.
Changes are documented
Modified software, parameters and resulting behaviour are traceable.
Permissive remains false without a clear alarm
Hidden conditions, latched faults, missing status bits and incorrect reset logic are traced to the blocking state.
Safety relay resets but automatic mode stays blocked
The physical chain may be healthy while PLC, mode logic, gate feedback or drive safety status remains unresolved.
A drive is ready locally but cannot be enabled
Enable paths, safety status, command source, control words and feedback are checked together.
A PROFINET device intermittently disappears
Device diagnostics, topology, connection quality, addressing and timing distinguish random symptoms from repeatable causes.
The same signal differs in PLC, CANape and DAQ
Scaling, units, byte order, source selection and conversion are compared across all systems.
A manual procedure reduces test repeatability
The process is mapped, permissives defined and selected steps become controlled, repeatable automation.
Diagnostic findings report
Confirmed symptoms, system state, probable causes, checked interfaces and supporting evidence.
Signal-trace matrix
Command, permissive, safety, output, feedback and sequence relationships for the affected function.
I/O verification record
Checked inputs, outputs, physical response, scaling and relevant device states.
Software & parameter change log
Modified logic, parameters, versions, reasons and verification activities.
Functional verification record
Tested operating modes, normal behaviour, fault reactions and restrictions.
Open-point & risk register
Outstanding issues, temporary measures, responsibilities and recommended follow-up.
Scope and responsibility are defined before modification. InnovaDrive can diagnose, integrate and functionally verify safety-related circuits and machine responses within the agreed project scope.
Formal safety validation, certification or legally required conformity assessment remains subject to the client's appointed responsible parties and applicable procedures.
Automation knowledge can become easier to retrieve and reuse.
NOVA can structure alarm histories, PLC documentation, fault-resolution records and approved procedures to support future diagnostics and handovers.
Need to resolve a control, communication or safety problem?
InnovaDrive provides hands-on diagnostics, modification and verification support for PLC systems, drives, industrial networks, safety chains and automated test sequences.