Example Projects & Architectures
To protect active operational security and confidential contract bounds, we do not publish proprietary customer names or proprietary figures. Instead, explore these detailed illustrative system profiles representing typical deployments.
System Application Concepts
Every profile illustrates a common industrial challenge and how the Ignition software can be structured to solve it.
SCADA Modernization Concept
Problem: A facility operates on legacy PC-based control screens with slower poll rates, suffering driver lockups and lack of historical trend export lines.
Solution Architecture: Implement a centralized Ignition Gateway connected to existing PLCs. Structure consistent UDTs to define digital assets. Create modern high-performance SCADA screens in Vision and stream tag history to a local PostgreSQL server.
Production & OEE Dashboard Concept
Problem: Supervisors must walk up to separate machine counters to check shift outputs, compilation is manual, and OEE is tracked days after runs complete.
Solution Architecture: Configure real-time count variables from local lines. Build interactive web-based OEE dashboards in Perspective, displayed on shop-floor overhead TV screens. Provide operators with popup screens on local touchscreens to classify downtime categories.
Perspective Mobile Web Application Concept
Problem: Maintenance technicians must walk back to the central control desk to acknowledge system faults and log pump hour parameters during walkarounds.
Solution Architecture: Design a secure, mobile-friendly Perspective client. Build a layout that stacks cleanly on tablets and smartphone displays. Integrate smartphone camera scanners to scan machine barcode tags and jump directly to that machine’s control popup faceplate.
Machine-to-ERP Data Integration Concept
Problem: Enterprise schedulers upload production orders into an ERP system, but operators must manually copy lot recipes and output details between screens.
Solution Architecture: Establish a bidirectional REST API connector inside Ignition's Python library. Program transaction lines that poll the ERP for daily work orders, push recipes directly down to PLCs, and log finished batch serials back to the database.
Alarm Consolidation & Routing Concept
Problem: Active sirens and flashing lists on local screens cause operator fatigue, leading to missed critical alerts and unscheduled line downtime.
Solution Architecture: Audit alarm parameters to install deadbands and timers. Structure dynamic alarm routing pipelines inside Ignition. If a critical motor alarm goes un-acknowledged for 3 minutes, automatically alert the on-call engineer via an encrypted SMS pipeline.
Report Automation & Distribution Concept
Problem: Maintenance leads spend the first hour of every shift query-compiling previous raw run logs, causing delays in scheduling maintenance priorities.
Solution Architecture: Configure layouts in the Ignition Reporting module with custom tables and bar graphs. Schedule the core gateway reporting engine to query the SQL database and compile a shift PDF report, delivered via SMTP email to supervisors at 06:00 AM.
Discuss Your System Architecture Goals
Contact us to explain your physical equipment counts, PLC platforms, and interface targets. We will design a custom illustrative proof of concept.
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