Procedure-Based Test Management
Configurable test steps create repeatable, standardized and controlled calibration flows for different device types.
Integrated Test and Machine Control Software for Torque Calibration Processes
Managing manual and automatic test flows within the same structure, this solution digitizes torque calibration operations end to end with a procedure-based working model, Beckhoff PLC integration, real-time data monitoring, image analysis and certificate/reporting capabilities
About the Project
This custom operating software, developed for a torque calibration machine, is designed to manage test processes and machine control operations from a single point. The project addressed operator interactions, process steps, machine commands and system feedback within an integrated structure.
On the software side, a powerful, maintainable and operation-ready desktop application was developed using WPF and C#; on the machine control layer, a reliable communication infrastructure was built with a Beckhoff PLC. This created a synchronized, stable and controllable working model between the software and the physical machine.
The solution does more than provide a user interface; it is positioned as a comprehensive industrial control software that manages end-to-end test flows, monitors machine states, guides the operator and helps the process run in a more standardized way.
On the software side, a powerful, maintainable and operation-ready desktop application was developed using WPF and C#; on the machine control layer, a reliable communication infrastructure was built with a Beckhoff PLC. This created a synchronized, stable and controllable working model between the software and the physical machine.
The solution does more than provide a user interface; it is positioned as a comprehensive industrial control software that manages end-to-end test flows, monitors machine states, guides the operator and helps the process run in a more standardized way.
Powerful Capabilities Designed for Industrial Use
Developed for a torque calibration machine, this operating software brings the entire process, from test management to machine control and from image analysis to reporting, together on a single platform.
Real-Time Control with Beckhoff PLC
Machine commands, sensor data and motion control are managed with low latency and high reliability over TwinCAT ADS communication.
Manual and Automatic Test Modes
Operator-controlled manual tests and procedure-based automatic test flows can be run flexibly under the same software framework.
Real-Time Data Monitoring
Load cell, angle and status data are monitored instantly; the dynamics of the process are shown live to the operator during the test.
Camera-Assisted Visual Analysis
For dial-type and click-type devices, camera-based analysis evaluates pointer behavior or the trigger moment as supporting data.
Tolerance and Safety Checks
Critical conditions such as mV overrun, angle drift, sensor disconnection and direction conflict are monitored to maintain operational safety and process stability.
Reporting and Certificate Management
Test results are recorded, historical data can be traced, Excel reports can be generated and certificate processes can be managed through the system.
User and Operations Management
Customer, device, reference sensor, procedure and user management are centralized, strengthening the sustainability of operations.
Technology
Technologies Used
C#
XAML
Beckhoff PLC
Live Test in the Laboratory
Footage of the software running in field conditions. When the operator starts the test, the PLC sends commands to the motor, the camera reads the scale at each step, and the software calculates the error rate and instantly reflects the result in the interface. This entire cycle runs from a single screen, without human intervention.
Outcomes
Transformation Achieved in the Process
With the new software, test, machine control, monitoring and reporting processes became more standardized, safer and more traceable.
Test Process Management
Scattered steps
Procedure-based workflow
Standardized
Machine Control Structure
Fragmented control
Central management via PLC
Single point of control
Result Traceability
Limited records
Recorded test history
Traceability improved
Operational Safety
Manual risk tracking
Automatic safety checks
Safer process
Test Data Collection
Focused on spot observation
Continuous data monitoring
Better data visibility
Reporting and Documentation
Manual output process
Excel and certificate generation
Documentation strengthened
Screenshots
Click an image to enlarge it.
More projects
Related Projects
Industry from the industry
Automatic Calibration Software for Length Measuring Instruments
An end-to-end software solution that combines PLC control, image processing and certification in a single interface, working integrated with the machine manufacturer's hardware.
2024 2 mo
Read
Have a similar project?
Share your needs and we will design and deliver a tailored solution.