// Industrial automation · Fairland, Johannesburg
Mechatronic solutions for complex problems.
Automation Republic is a team of mechatronic engineers who develop and seamlessly integrate innovative industrial automation solutions — from machine retrofits to turnkey production lines.
How we do it
Simple and effective mechatronic solutions for complex problems
How we do it
Aligned to industry leading technology partners
How we do it
Zero compromise approach to quality
How we do it
Expertise and ongoing support for all our solutions
// From the case studies
67
solar trackers re-controlled
23 at one plant, 44 at another, on one new controller each
1 800 t
REMU injection moulding machine
control system upgraded and back in production
25 yr
old Italian pipe-end former
re-engineered from the panel up
15
industries served
from mining and marine to pharma and print
// Live line · tap a machine to see the project
Machines that move.
Injection Molding 3D democycling
Wire Forming 3D demofeeding
6-Axis Robotpick & place
3-Axis Gantrypick & place
Heavy Machineryearthmoving
Conveyor & Sortation 3D demorunning
SCADA & HMIlive
Software Devbuilding
Coding & Datingprinting
Rotary Labelingapplying
Laser Markingmarking
VFFS Bagger 3D demopacking
// Services
From one panel to a whole line.
We provide a team of experienced professionals committed to resolving not only the immediate challenge but also to delivering the most effective long-term solution for your business.
// Built on B&R X20
A control system, module by module.
- B&R X20 rackCPU and I/O slices slide onto the rail as one system: POWERLINK and Ethernet on board, I/O on the X2X Link backplane.
- OnlinePower on: the CPU boots, the bus comes up and every channel reports in.
- Talks to SiemensAn existing S7-1200 joins over Ethernet. Modbus TCP and PROFINET let B&R and Siemens share one machine.
B&R parts from B&R’s own CAD data · multi-brand
The machine
A · boomB · bend pinY · wire feed
Existing machineframe · mechanics · valves · sensors kept
Field wiring & I/O
X2 · field terminals
1234567891011121314151617181920212223242526272829303132
-B12Prox, feed home
-B14Encoder, wire length
-Y21Crop valve
-S03Guard door 2
-S01E-stop, operator
-M30Decoiler motor
PLC & drives
Control panel · =CP1POWERLINK 4 nodes
PSX20 PS9400
CPUX20 CP1486
DIX20 DI9371
DOX20 DO9322
AIX20 AI4622
AOX20 AO4622
X1 · 24 VDCX2 · I/OX3 · drives
123456789101112131415161718192021222324
ACOPOS P38EI4X5HWD
RUN
RDYRUNERR
Ax 1 · A boom0.0°
Ax 2 · B pin0.0°
Ax 3 · Y feed0 mm
HMI & software
WB-01 · Wire benderOverviewAUTO08:42:10
A · boom0.0°
B · bend pin0.0°
Y · feed0 mm
C · crop0.0 mm
Step 3 / 7 · bend 90°
Parts1 284
Cycle4.2 s
Rate14 /min
OEE87 %
No active alarms · 4 POWERLINK nodes OK
Remote support
Remote supportVPN tunnel up · 18 ms
WB-01Wire bender
WB-02Wire bender
TRK-23Solar tracker
CS-50Pipe end former
Update pushed 07:12 · software v2.4.1 · no site visit
// Anatomy of a retrofit
One machine in. A better machine out.
Scroll to take a machine apart the way we do: keep the sound mechanics, then rebuild the control system layer by layer.
Keep what is soundWe start by evaluating every piece of existing hardware. The frame, mechanics, valves and sensors that still work stay; only what is holding the machine back is replaced.
Rewire to the fieldLegacy relays, old control boards and dead wiring come out. A new electrical layout goes in, with every field device identified, terminated and tested.
New PLC and motionA B&R X20 PLC and ACOPOS servo drives over POWERLINK give coordinated, real-time motion, all engineered in one Automation Studio project.
HMI and software, written in-houseSequencer, recipes, diagnostics and interlocks, written from scratch and tested on the machine. You own the code and the documentation.
Supported remotelyVPN remote support keeps the machine tuned and updated without waiting for a site visit.
24/7 Technical Support
We can help you overcome any hurdles you might be facing.
// HMI software
Screens operators actually use.
Every HMI is written in-house around how the machine is run: live axes and counters, alarms in plain language, trends logged for fault-finding, and recipes set up on screen instead of in code. Example screens from a wire bender.
WB-01 · Wire benderOverviewAUTO08:42:10
A · boom0.0°
B · bend pin0.0°
Y · feed0 mm
C · crop0.0 mm
Step 3 / 7 · bend 90°
Parts1 284
Cycle4.2 s
Rate14 /min
OEE87 %
No active alarms · 4 POWERLINK nodes OK
WB-01 · Wire benderAlarmsAUTO08:42:10
| Time | Code | Message |
|---|---|---|
| 08:41:52 | W 3021 | Wire feed slip above 0.4 mm, compensating |
| 08:12:07 | I 1004 | Recipe BRK-118 loaded by operator 02 |
| 07:58:31 | E 7110 | Guard door 2 opened in AUTO, axis stop |
| 07:58:44 | I 1002 | Guard closed, acknowledged, axes homed |
| 07:41:18 | W 2207 | Decoiler tension low, feed rate reduced |
| 07:22:05 | I 1010 | Lubrication cycle complete, bend head |
| 07:03:44 | E 5402 | Y axis following error, feed blocked, axis stop |
| 07:04:30 | I 1002 | Fault acknowledged by operator 02, axes homed |
| 06:48:12 | I 1006 | Wire coil changed, 4 mm, length counter reset |
| 06:30:00 | I 1000 | Shift A start · 0 parts |
1 active warning · 0 faults · 10 events this shift
WB-01 · Wire benderTrendsAUTO08:42:10
Feed speed, mm/sServo current, Alast 15 min
Logging to CSV · 10 ms sample
WB-01 · Wire benderRecipesAUTO08:42:10
BRK-118 · bracket, 4 mm wire7 steps · 1.2 s feed · saved 06 Oct
| Step | Feed mm | Bend ° | Boom ° |
|---|---|---|---|
| 1 | 120 | — | — |
| 2 | — | 90 | — |
| 3 | 64 | — | — |
| 4 | — | 90 | — |
| 5 | — | — | 45 |
| 6 | 38 | — | — |
| 7 | — | 135 | — |
Recipe valid · limits checked
// Our range of projects
Experience across a diverse range of industry sectors.
// Our industries
Fifteen industries, one standard.
Experience across a diverse range of industry sectors, aligned with global technology leaders.
PlasticsFood & BeveragePharmaceuticalAutomotiveConstructionPaper & PrintWoodTextileElectronicPackagingCosmeticMetal WorkingMarineMiningEnergy
Find out more →// Aligned to industry-leading technology partners
