Low-Code PLC Programming Ecosystem Validation

Project challenges

Traditional Programmable Logic Controller (PLC) programming is highly complex, relying on extensive text‑based code and specialist expertise, which makes development slow and difficult to maintain. It is difficult to keep control logic consistent across different PLC brands, as each vendor requires its own programming approach, reducing scalability. In addition, large codebases quickly become hard to read and maintain, making updates or reviews time‑consuming. Integration work is another major challenge, as deploying code to the PLC requires many manual configuration steps that increase the chance of errors. PLC workflows are often poorly documented, leading to inconsistencies and making it difficult to standardise processes within and across projects.

A low‑code development ecosystem can simplify PLC programming by allowing engineers to create control logic using graphical models rather than traditional text‑based coding. Such platforms typically include tools for building class, state, and activity diagrams; runtime communication services; and commissioning dashboards for real‑time monitoring and control. The goal is to reduce programming complexity, improve readability, and enable cross‑platform deployment across different PLC brands.

A model‑driven approach helps overcome these challenges by introducing a unified, structured way of developing and deploying PLC logic. It can automatically generate code for both PLCs (structured text) and edge/PC platforms (C#), improving consistency and reducing manual effort.

MTC's solution

To address the challenges, MTC adopted a structured approach centred on low‑code technology. Cordis Suite was selected as the platform for developing PLC control logic using graphical modelling rather than traditional text‑based programming. This choice aimed to reduce complexity, improve readability, and enable future cross‑platform compatibility.

The solution involved several key steps:

• Demonstrator Development — Recommissioned the hairpin bending rig as an industrially relevant testbed to validate low‑code programming in a real‑world scenario.
   
• Training and Knowledge Building — Conducted in‑depth Cordis Suite training covering model‑based design, runtime operation, and integration workflows.
   
• Integration Trials — Implemented Cordis‑generated code on Beckhoff TwinCAT hardware, documenting the process and resolving compatibility and configuration challenges.
   
• Workflow Definition — Established a repeatable methodology for low‑code deployment, including best practices for safety integration, manual configuration, and troubleshooting.

This structured approach not only demonstrated the feasibility of low‑code PLC programming but also provided a foundation for future projects requiring rapid deployment and modular automation.

The outcome

Capability Assessment — The demonstrator effectively tested the applicability of low‑code PLC approaches in an industrial context, enabling a clear assessment of where the technology can and cannot be deployed.

Enhanced Readability and Maintainability — Transitioned from traditional text‑based programming to a graphical, model‑driven approach, improving clarity and reducing complexity for future updates.

Key Insight on Trade‑offs — Identified that unlocking the benefits of low‑code PLC development requires upfront effort to correctly structure code for hardware integration, with this investment delivering clear value in larger, more complex projects.

Benefits to industry

Accelerated Development — Significantly reduces programming time for complex machine behaviours through intuitive, model‑based design.

Cross‑Platform Flexibility — Enables deployment of identical control logic across multiple PLC brands, supporting interoperability and future‑proofing.

Rapid and Modular Automation — Enhances capability for fast integration and scalable automation solutions, aligning with industry needs for agility and cost efficiency.