MACHINE AUTOMATION
​​
-
Machine Automation
-
6DOF Stewart Platforms
-
Motion Systems
-
OEM Equipment Integration
-
HMI Design & Integration
CLICK HERE: What We Use?
Automation Support
for
OEM Machine Builders
Human Machine Interfaces
We support OEMs, machine builders and industrial equipment manufacturers with practical machine control and automation engineering focused on real-world performance, reliability, and lifecycle support.
​
From standalone machines to multi-system automated equipment, we design and implement control solutions that keep machinery operating consistently, safely, and efficiently in the field.
​
We are not electrical contractors. We work alongside them — providing the control, integration, and automation expertise that brings machine systems to life.
OEM Control
&
Automation Engineering
We provide support across the full machine control stack, including:
​
-
PLC & HMI programming
-
Machine control architecture design
-
Servo motion & VSD / VFD integration
-
Distributed / networked control systems
-
Industrial communications and telemetry networks
-
Safety system integration
-
Control panel specification & support
-
Commissioning assistance & on-site support
-
Fault finding and system optimisation
-
Legacy system upgrades and retrofits
Our focus is simple: build control systems that are
practical, stable in operation, and easy to support long-term.
​
Good automation is not defined in simulation or commissioning tests — it is proven in daily operation.
Legacy Hardware Upgrades & Modifications
TAURUS BALER
The upgrade was primarily developed to support the integration, commissioning, maintenance, and long-term support of a refurbished legacy asset, including the addition of an auxiliary control system operating alongside the existing machine control architecture. However, it also delivered significant operational benefits to the end user through improved fault visibility, reduced downtime, and faster recovery from machine stoppages.​
A modern HMI was also added to significantly improve operator visibility and interaction, delivering a clearer interface for real-time machine status, alarms, and system health. The upgrade included pressure and temperature monitoring, runtime tracking, user activity logging, maintenance scheduling, alarm management, and smart diagnostic logic capable of identifying sensor and feedback anomalies. This approach enabled modernisation of machine insight and maintainability while respecting the constraints and proven stability of the original 1990s control architecture.
Supporting
OEM
Development
Legacy Hardware Upgrades & Modifications
TAURUS BALER
A legacy upgrade was completed on an early 1990s-era Taurus 600-ton baler shear that had been sourced as a refurbished machine for installation and commissioning at the end user's site. As the equipment was supplied with an existing control platform and remained under warranty, the original PLC architecture and operating system were retained to preserve warranty coverage and simplify ongoing support.
To facilitate long-term maintenance and serviceability, an auxiliary PLC architecture was engineered and integrated alongside the legacy control system. Rather than replacing the core machine controls, the new platform provided enhanced diagnostics, monitoring, fault logging, and maintenance functionality while allowing the original operating system to remain unchanged.
The additional control logic enabled authorised maintenance personnel to access an engineering mode, providing controlled manual machine movements, selective limit bypass functions, advanced fault diagnostics, and recovery capabilities for maintenance and troubleshooting activities.
Built for
Real Machines
We design systems around:
​
-
Reliable machine sequencing
-
Stable communication between devices
-
Predictable motion and process control
-
Maintainable programming structures
-
Practical diagnostics and fault recovery
-
Reduced downtime and operational complexity
The goal is not complexity — it is control that behaves consistently under real-world conditions.
Actual implementation of legacy hardware upgrade
We act as a technical extension of OEM engineering teams
during design, build, and deployment.
This includes:
​
-
Control system design input during machine development
-
Programming and integration support
-
Coordination with electrical and mechanical contractors
-
Third-party equipment integration
-
Commissioning and on-site troubleshooting
-
Production stabilisation and optimisation
We also help OEMs deliver machines that are:
ready to run — not just ready to assemble.
Actual HMI panel build for legacy hardware upgrade
Practical Engineering
No
Unnecessary Complexity
Schneider Zelio PLC and Magelis HMI with
MODBUS SERIAL and MODBUS TCP/IP control options
We prioritise engineering decisions that improve performance, reliability, and maintainability — not unnecessary system complexity.
Every solution is designed with long-term operation in mind:
​
-
Easy to diagnose
-
Simple to maintain
-
Robust under production conditions
-
Scalable where required
-
Consistent across deployments
Real projects. Real engineering. Real automation.
If you value directness, honesty, accountability, facts over fiction and a partner who focuses on
real outcomes over noise, Align Automation is built for that.
Align Automation
Precision Engineered | Alignment Driven