Control Technology & Automation
From the first circuit diagram to global commissioning.
HDAO Controls develops, programs, and integrates control solutions for manufacturing and assembly lines as a certified Siemens Solution Partner with deep OEM expertise for BMW, Mercedes-Benz, and Volkswagen.
Control technology from a single source, from planning through ongoing operation.
Whether it’s a new production line, assembly automation, machine modernization (retrofit), or complex system integration: HDAO Controls takes full responsibility for your automation projects worldwide—from electrical design and PLC programming to commissioning.
Our customers benefit from a dedicated point of contact, clearly defined responsibilities, and proven project experience in the automotive and special-purpose machinery industries.
PLC Programming
Software development in accordance with IEC 61131-3 on all common Siemens platforms: S7-1500, TIA Portal, SINUMERIK 840D, Safety Integrated. We program in accordance with the standards specified by your OEMs, from BMW to Mercedes-Benz to VW/PowerCo.
Control Cabinet Construction
From single cabinets to mass production: We build control cabinets, control consoles, and terminal boxes according to your specifications, in batch sizes ranging from 1 to 180 units per series. Mechanical machining and cable assembly are included.
Electrical Design
Circuit diagrams in EPLAN, hardware and network design, component and safety specifications, bills of materials, and thermal calculations. Upon request, we can comply with your end customer’s standards, even without a manufacturing order.
Robot Programming
Programming and commissioning of Kuka KRC2/4/5, ABB, and Fanuc robots in accordance with the robotics standards of BMW, Mercedes-Benz, and VW. For welding, handling, assembly, and testing applications in mass production.
Commissioning
We commission your system: I/O check, safety and interface tests, system startup, and acceptance testing. Virtual validation available upon request. In Germany, Europe, Asia, and the Americas.
Electrical Assembly & Installation
Cable routing, cable pulling and connection, cabinet setup and field installation, sensors, actuators, and drives. Including measurement and testing in accordance with DGUV V3 and a documented handover.
Retrofit & Relocation
Outdated control systems compromise system availability and spare parts reliability. We’ll migrate your systems from Siemens S5 to S7 or TIA Portal—without any production downtime—and provide complete documentation and validated functional testing.
Maintenance & Servicing
Every hour of downtime costs production. We keep your control systems up and running: with remote maintenance, scheduled maintenance intervals, and rapid on-site troubleshooting. In the DACH region, we respond in under 24 hours—with a fixed response time included in the service contract upon request.
When will we get started on your project?
Whether you need short-term capacity or are planning a full-scale project, please tell us what you need. Our team will review your request personally and get back to you.
Programmed to meet your OEM standards
Automotive manufacturers and Tier 1 suppliers work with mandatory programming standards. At HDAO Controls, we don’t just know these standards from textbooks—we apply them every day. This eliminates the need for repeated rounds of coordination, speeds up the approval process, and ensures your quality requirements are met.
BMW Group
PLC programming standards: TKB, TMO V3, and GSC. Visualization using WinCC and WinCC Unified. Robotics using KUKA KRC4 and KRC5 according to customer specifications. Electrical design in Eplan using the SAS tool and in accordance with best-practice guidelines.
Mercedes-Benz
PLC programming standards: Integra and Powertrain. Visualization with WinCC, WinCC Unified, and Transline. Integration of Prisma and Zell systems. Robotics with KUKA KRC4 and KRC5, ABB, and Fanuc according to customer specifications. Electrical design in Eplan according to PPA specifications.
Volkswagen / PowerCo
VASS programming standard. Visualization using WinCC, WinCC Unified, and Transline. Robotics with KUKA KRC4 and KRC5, VKRC, ABB, and Fanuc according to customer specifications. Electrical design in Eplan.
Projects that speak for themselves.
From two linked module assembly lines in the e-mobility sector to a complete control system retrofit of a final test station: Our references demonstrate what we mean when we talk about automation expertise.
's Module Assembly Line for E-Mobility
Complete control system for two module assembly lines. Siemens S7-1516F with Safety Integrated, Keyence vision systems for quality assurance, integration of HIPOT testing, plasma cleaning, pressing, bonding, and welding processes, as well as integration with the higher-level control system.
Control System Retrofit of an
Hybrid Final Test Station
Upgrade of a final test bench for hybrid drives from the second to the fourth generation, carried out as the general contractor. Control system replacement from S7-300 to S7-1518F in the TIA Portal, switch from PROFIBUS DP to PROFINET, new visualization system, retrofit of the conveyor system, and replacement of all RFID devices.
Four Shuttle Systems for
Intralogistics
Control cabinet construction, electrical assembly, and installation of four level-linked shuttle systems, each spanning 35 meters, in the logistics facility of a cosmetics manufacturer. Connection of the conveyor controllers via ASi bus, designed for reliable continuous operation in a shift-based production environment.
A competitive edge starts with knowledge.
We're curious to see
which project inspires you.
Whether it’s control system design, automation, or modernization, together we’ll find the right solution.