With over 40 years of expertise, Messung offers a reliable solution to enhance productivity in automotive manufacturing.

The XMPRO-10 PLC from Messung is designed to meet the automotive industry’s demands for precision, speed, and quality. Equipped with high-speed processing, seamless connectivity, and compatibility with IIoT, MQTT and PID control, the XMPRO-10 PLC streamlines production processes. Paired with Messung’s XMPS-2000 software for effortless programming and monitoring, it’s an ideal choice for achieving efficiency and maintaining quality standards.

Key features of the Messung XMPRO-10 PLC for the automotive industry

The XMPRO-10 PLC is built to address the growing needs of the automotive industry, offering flexibility, scalability, and advanced functionalities. Here are some of the key features that make it an ideal choice for automotive automation:

• High-Speed Processing: The XMPRO-10 PLC is engineered for fast and efficient execution of control tasks. In time-sensitive automotive applications like robotic assembly, conveyor systems, and painting booths, this fast processing is crucial to maintain smooth and uninterrupted operations.

• Scalability: The modular design of the XMPRO-10 PLC makes it a highly scalable solution. As production lines expand or the need for additional machines arises, the system can easily adapt, making it suitable for both small assembly lines and large-scale automotive plants.

• Advanced Connectivity: Fully equipped to integrate with Industry 4.0 systems, the XMPRO-10 PLC supports protocols like Ethernet/IP, Modbus TCP, and MQTT. This enables seamless communication with SCADA systems, cloud platforms, and enterprise software, allowing for efficient data exchange and remote monitoring.

• Energy Efficiency: Designed to minimise power consumption, the XMPRO-10 PLC helps automotive manufacturers reduce their operational costs and environmental impact, making it a more sustainable solution.

• User-Friendly Programming: The XMPRO-10 PLC comes with the intuitive XMPS-2000 programming software, which simplifies the process of developing, testing, and deploying automation strategies. This user-friendly interface ensures a smooth experience for engineers, even when working with complex systems.

• Retrofitting Capabilities: One of the standout features of the XMPRO-10 PLC is its ability to upgrade legacy PLC systems. By integrating modern capabilities into existing equipment, manufacturers can ensure a seamless transition to a more advanced and high-performance automation system without the need for a complete overhaul.

Why choose the XM-PRO 10 PLC?

The XM-PRO 10 PLC combines advanced technology with Messung’s legacy of excellence to deliver unmatched versatility and performance.

Key Features

• Compact Yet Powerful: 17 onboard I/Os with expandable up to 80 I/Os or 5 units using modular expansions.

• User-Friendly Design: Simplifies wiring, installation, and fault identification with pluggable terminal connectors, DIN rail mount assembly, and diagnostic LEDs.

• Configurable I/Os: Supports Digital and Analog I/Os configurable for diverse applications.

• Integrated Connectivity: Built-in Modbus RTU (Master) and Modbus TCP (Client/Server) eliminate external converters.

• Future-Proof Performance: Designed to integrate with modern industrial networks and IoT platforms.

Applications across industries

The XM-PRO 10 PLC is versatile and finds applications across a wide range of industries:

- Automotive: Pressure Testing, Conveyor Automation, Robotic Cells.

- Food Processing: Packaging, Labeling, Sorting, Temperature Control.

- Plastics: Injection Molding, Blow Molding Automation.

- Printing: Print Line Automation, Paper Sorting Systems.

- Textiles: Weaving, Dyeing, and Finishing Machines.

- Machine Tools: Hydraulic Presses, Drilling & Tapping, Press Machines, and Drilling Machines.

Automotive sector case studies: Messung XMPRO-10 PLC in action

Here are the bullet points for each of the automotive applications:

1. Automotive Assembly Line Optimisation:

• Implemented Messung XMPRO-10 PLC to automate engine assembly line processes.

• Synchronised robotic arms, conveyors, and sensors for seamless operation.

• Reduced production time and minimised human error.

• Increased production throughput while maintaining consistent quality.

• Enhanced overall efficiency and automation in the assembly process.

2. Paint Shop Automation:

• Integrated XMPRO-10 PLC into the paint spraying process for precision control.

• Managed spray guns, temperature, and drying times to ensure uniform paint application.

• Enabled remote monitoring and adjustment of the system, improving operational flexibility.

• Reduced material waste and enhanced energy efficiency.

• Contributed to cost savings and environmental sustainability in the painting process.

3. Robotic Welding Applications:

• Retrofitted existing PLC systems with Messung’s XMPRO-10 PLC to optimise robotic welding stations.

• Enhanced communication between the PLC and robotic systems for smoother operations.

• Leveraged advanced motion control features for faster, more accurate welding.

• Reduced defects and improved overall product quality.

• Boosted production speed and ensured reliable quality control in welding operations.

Retrofitting old PLC systems with the XMPRO-10 PLC

Legacy PLC systems often struggle to meet modern automation demands or integrate with new technologies, making upgrades costly and disruptive. Messung's XMPRO-10 PLC offers a cost-effective solution by enabling seamless retrofitting of old PLCs. For example, in an automotive plant, replacing outdated PLCs with XMPRO-10 PLC enhances capabilities like advanced motion control and faster data processing while maintaining existing equipment. This approach extends machinery life, modernises operations, and ensures minimal production downtime.

MQTT connectivity: The future of industrial automation

The XMPRO-10 PLC stands out with its support for MQTT, a lightweight protocol ideal for industrial IoT applications. MQTT enables real-time data transmission, even over low-bandwidth or unreliable networks, making it perfect for automotive manufacturing environments.

With MQTT, the XMPRO-10 PLC can send factory floor data to cloud platforms or SCADA systems, allowing remote monitoring of robotic arms, conveyors, and sensors. This ensures real-time insights, predictive maintenance, and faster decision-making. Its low overhead supports reliable communication in bandwidth-constrained settings, enabling seamless connectivity across devices and advancing Industry 4.0 initiatives.

PID control: Precision and stability

The XMPRO-10 PLC features advanced PID (Proportional, Integral, Derivative) control for precise process regulation. Ideal for applications like temperature control in paint booths or speed regulation on conveyor systems, it ensures consistency and efficiency. For example, in automotive paint booths, PID control maintains stable temperatures, ensuring uniform paint curing. Similarly, in automated testing, it regulates pressure and speed for consistent results. By minimising variations, the XMPRO-10 PLC enhances quality, reduces defects, and optimises production, making it a perfect fit for precision-driven industries like automotive manufacturing.

Real-time example: Pressure testing machine

In the automotive sector, the XMPRO-10 PLC excels in quality control, such as pressure testing for components like fuel tanks and brakes. Integrated into testing machines, it uses PID control to maintain precise pressure levels, ensuring components meet specifications without human intervention. Its MQTT feature enables real-time monitoring, transmitting data like pressure levels and test results to SCADA or cloud platforms for remote oversight. This enhances quality assurance, boosts efficiency, and enables rapid responses to anomalies.

Conclusion

Messung’s XMPRO-10 PLC offers a powerful, flexible solution for automotive manufacturers looking to enhance their automation processes. With its high-speed processing, scalability, MQTT connectivity, and advanced PID control, the XMPRO-10 PLC provides an all-in-one solution for improving efficiency, precision, and real-time monitoring in automotive production environments. Whether retrofitting legacy systems or implementing new automated applications, the XMPRO-10 PLC is equipped to meet the evolving demands of the automotive industry, ensuring manufacturers can stay competitive and maintain the highest standards of quality. 

Farook Merchant, Chairman & MD, Messung Group

Mr Farook Merchant, CMD of Messung Group, founded Messung Systems in 1981 with a vision to provide cost-effective automation solutions. As an Electronics Engineer, he designed India’s first Programmable Logic Controller and developed advanced PLCs with international standards. Under his leadership, Messung has grown into a leading group with over 100 employees, a diverse product range, and global partnerships, focusing on Automation & Control and Workplace Technology. 

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