Controls and Software
from a single source
One partner. Maximum usability. Fully integrated.
Many Sonplas customers face the challenge that product development, process design, and machine procurement take place almost in parallel—while being under significant time and investment pressure. Especially under these conditions, isolated software solutions, distributed control logics, or subsequently integrated data concepts quickly reach their limits.
Sonplas addresses these challenges with a holistic system approach: technology and software are an integral part of the machine and the entire production process from the very beginning. Our systems are consistently developed as fully integrated solutions—not as a combination of isolated components. Automation, measurement and testing logic, safety, data management, and HMI are all handled from a single source, without black boxes or critical dependencies on third-party providers.
Your advantages
with Sonplas at your side
One system. One responsibility. One partner.
At Sonplas, you receive everything from a single source: automation, robotics, measurement technology and software tools work seamlessly together. Instead of isolated standalone solutions, we develop your system as an integrated overall solution. Complemented by our strong in-house expertise in machine vision and electronics development, we create solutions that remain reliable and fully controllable.
State-of-the-art control architecture – fast, robust and integrated
The optimal control concept for your application: through a high level of integration, we reduce interfaces to a minimum and create a consistent, intuitively operable system. Cyber security is integrated from the very beginning. A data-driven, open system for your smart factory – ensuring maximum connectivity and full transparency in production.
Software-defined functionality – flexible, integrated, and future-proof
Our systems are built on a software-defined architecture, enabling the flexible production of a wide range of products – up to batch size 1 with minimal changeover effort. Integrated inline and end-of-line testing create closed-loop control systems that continuously monitor and specifically optimize the production process.
Integrated process analysis – real-time transparency
We capture and store more than just standard process and test results – directly within the system. Our integrated software tools process the data in a way that deviations become visible at an early stage, enabling well-informed decisions directly in production—without additional tools or manual analysis.
Usability in focus – for high system availability
Our HMI solutions are consistently designed with the operator in mind. Clear, intuitive visualization, role-based information, and integration with the digital twin ensure quick orientation during operation. Error messages can be supplemented directly within the HMI and extended with troubleshooting instructions. Fewer errors, faster response times—for higher system availability.
One partner throughout the entire lifecycle
From commissioning to long-term operation, Sonplas provides you with a dedicated point of contact – ensuring clear responsibility for performance, availability, and continuous optimization of your system. We support you reliably throughout the entire lifecycle.
Our control and software solutions – click for more information:
Digital twin Virtual commissioning Human-Machine-Interface Smart Documentation Control platforms Machine and SonVision
How we combine mechanics and software
into one integrated system
From simple manual assembly to high-speed applications and advanced metrology: different requirements demand flexible software concepts – while maintaining high usability, process reliability, and system availability during operation.
Our answer is a consistent control architecture. Process logic, metrology, automation, data analysis, and HMI are centrally integrated and form a unified software platform – without isolated solutions or unnecessary interfaces. The result is a system that can be operated consistently and remains fully controllable at all times.
A key element is our modular software toolkit. Based on reusable, field-proven modules, we develop tailored solutions for each system – without copy-paste engineering. Model-based engineering and AI-supported code generation ensure high software quality, shorter development times, and reduced project risks.
Digital Twin – your advantage throughout the entire lifecycle
Our approach deliberately goes beyond the usual standards in special-purpose machinery: we seamlessly integrate mechanics, electrics, pneumatics, hydraulics, and software into a consistent overall system – our digital twin. This creates real added value for both you and us, from planning and commissioning through to operation, service, and continuous optimization of your system.
The digital twin delivers its value particularly in three key areas:
In virtual commissioning it enables early simulation and significantly reduces commissioning time. Within the HMI, it ensures intuitive, visually guided operation, and in Smart Documentation, it connects all engineering domains – from the 3D model and EPLAN to hydraulic and pneumatic schematics.
Virtual Commissioning
As part of the digital twin, virtual commissioning enables the simulation of the complete system process before the actual build. The control system is linked to the digital machine model, allowing sequences, logic, and movements to be tested and optimized at an early stage. This increases software maturity and significantly reduces commissioning time on the real system.
Your benefits:
- Fewer trial parts and lower costs
- Faster system delivery
- Shorter implementation times for changes—even during ongoing operation
- Early error detection and reduced risk during modifications
Usability in focus –
for high system availability
Our approach to usability goes beyond the HMI and covers the entire handling of the system – from operator guidance with assistance functions to documentation and remote maintenance.
Our HMI is consistently aligned with the machine and intuitively guides the operator through the process. Machine states, sequences, and functions are presented in a clear and structured visual way. The result is an interface that actively supports the user: context-based functions lead directly from a message to its root cause and the appropriate solution. Error messages can be supplemented within the HMI and extended with troubleshooting instructions.
Optionally, an integrated 3D viewer – as part of the digital twin – enhances the HMI with a realistic visualization of the system. Errors are visualized in real time within the 3D model and can be located immediately. Components are directly linked to their corresponding software functions.
Integrated analysis tools provide real-time transparency: process data is visualized directly within the HMI. With the Sonplas Signal Analyzer – an integrated oscilloscope – process states become tangible and measurement sequences are displayed transparently.
The deep integration with SonDaSys (Sonplas Data System) ensures that process specifications and results are consistently visible and traceable.
Smart Documentation
We place great importance on modern system documentation that provides you with all relevant information quickly and clearly at any time. Instead of static documents, you can access all relevant information directly within the system – linked to the real machine and its components. Using the 3D model, components can be clearly identified and directly connected to the corresponding documents, circuit diagrams, or spare parts.
By directly linking mechanical, electrical, pneumatic, and hydraulic components, a consistent and structured documentation is created that is intuitive to use. Maintenance, service, and troubleshooting become significantly more efficient, as all information is available in context without time-consuming searches. At the same time, the documentation remains up to date and automatically adapts to changes in the system.
Smart Documentation
use data in a structured way
In addition, a central data foundation forms the basis for advanced analysis and sustainable optimization. Production data is systematically collected, stored, and made available for evaluations and reporting. This enables well-informed decisions based on historical data and supports the continuous improvement of your processes.
Standardized interfaces allow seamless integration of data into higher-level systems such as MES or ERP, making it accessible across the entire organization. At the same time, scalable and secure architectures ensure reliable availability and long-term expandability.
Your benefits:
- All relevant documents available directly at the machine
- Fast access via 3D model and clear structure
- Reduced effort in maintenance and service
- Direct linking of components, data, and documents
- Faster troubleshooting and maintenance
- Up-to-date documentation without version conflicts
- Support for spare parts management and service processes
Which control platforms
we use for your applications
For our machines, we use a range of established control platforms to optimally meet both application-specific requirements and customer-specific preferences. A particular focus is placed on data management and connectivity: through integration with SonDaSys (Sonplas Data System), we enable traceability, process analysis, and production control. Depending on the application as well as customer requirements and preferences, we select the appropriate technology – from classic PLC systems and PC-based control solutions to hybrid approaches.
Beckhoff TwinCAT
When, in addition to classic automation, very high performance, the integration of metrology, or computationally intensive tasks are required, Beckhoff control technology is the optimal choice. Cycle times of sometimes well below 100 µs, fast data acquisition, and virtually no memory limitations enable stable and high-performance processes – from simple manual assembly stations to highly complex laboratory test benches, including ATEX environments.
The platform combines control, motion, safety, and high-precision metrology within a single, consistent real-time system.
Thanks to its openness and performance, Beckhoff is the “one-fits-all” system for Sonplas across nearly all applications – offering you maximum flexibility, simplified operation through fewer subsystems, and highest productivity.
Siemens S7
When the focus is on assembly technology, Siemens S7 is the proven choice. As the de facto standard for automation in Europe, the platform stands for high reliability, robust hardware, and broad acceptance in the industry—from simple manual assembly stations to large automation lines with numerous process integrations.
The platform combines control, motion, and safety within a consistent system and is particularly well suited for stable, maintenance-friendly automation solutions.
The systems offer strong diagnostic capabilities and are familiar to maintenance personnel in many plants—resulting in faster troubleshooting and high system availability.
PC-based control
When conventional PLC solutions reach their limits, PC-based control is the right choice. Built on a Beckhoff Soft PLC within the same system, this platform is ideally suited for complex applications such as AI-based machine vision, real-time data analysis, or the implementation of process-related algorithms.
By combining all control tasks within a single hardware platform, a powerful and flexible system architecture is created. The platform is scalable—from cost-efficient solutions to high-performance systems—and enables the logging and storage of large volumes of data while maintaining high connectivity.
This gives you maximum freedom in implementing demanding applications.
NI TestStand (National Instrument)
When high flexibility for measurement applications is required, NI TestStand is the ideal platform. Especially in power electronics, TestStand enables the efficient integration of measurement devices, power supplies, electronic loads, and test sequences into a consistent test system.
Typical applications range from functional, dielectric strength, and insulation tests to load tests under simulated environmental conditions. TestStand is also used in injection technology and system testing.
Within the machine, TestStand is based on a Beckhoff PLC and integrates additional technologies such as LabVIEW and .NET.
This provides you with maximum flexibility in implementing new measurement tasks on a reliable, PLC-based system – while ensuring seamless integration into your Sonplas production line.
Machine Vision
How do you benefit from our expertise?
We provide complete machine vision solutions – from hardware selection and software development to after-sales support – ensuring stable process and quality control.
We work with a wide range of vision systems from leading manufacturers such as Keyence and Cognex. Thanks to many years of strong collaboration with these global players, we have access to a broad portfolio ranging from intelligent vision sensors to high-end image processing systems.
In our Sonplas laboratory, we develop customized solutions tailored to your requirements and test them thoroughly. Our vision specialists bring many years of experience, combined with continuous training on the latest technologies.
In addition to rule-based image processing algorithms, AI-based methods are also part of our daily toolkit. These include, among others:
- Edge learning
- Deep learning
- AI classification
- AI detection
- AI OCR
- AI segmentation
For implementing inspection tasks, we rely both on the powerful standard software of leading manufacturers and on our own developments. This allows test results to be flexibly visualized, evaluated, and tailored to your specific requirements.
SonVision
One partner. One software solution.
Our in-house vision software, SonVision, is continuously developed to deliver customized, high-performance solutions at the highest technical level – efficiently and economically. SonVision enables reliable anomaly detection through the creation of neural networks. Image data is automatically analyzed, and deviations from previously learned normal conditions are precisely identified. In addition, rule-based standard image processing tools are available to implement inspection tasks efficiently and flexibly.
To ensure sustainable use of the systems, we offer customer training focused on the deployed hardware as well as the structure and workflow of the respective inspection programs.
With our comprehensive expertise in machine vision, we do not simply offer “products,” but rather tailored, application-specific solutions.
Get in touch with us to explore how we can work together to increase the efficiency and quality of your production processes using machine vision.
