Systems Integration

How Do We Do It?

Our Methods


FLANDERS begins each project by working with our customers to define the functional goals of the system. This understanding guides every facet of the project’s execution. The system configuration translates functions into the necessary hardware and illustrates how these components interact. Upon customer approval of these primary documents, FLANDERS continues with the detailed design of the system.

The detailed design documents include a program organization plan, an explanation of the functionality’s functionality, and the system schematics. The software and system are developed and built using these documents, a test plan to test the functionality defined at the project’s initiation. Customer participation is strongly encouraged throughout all phases of development.

Process Benchmarking

For retrofits, site visits are made to define the current performance and operating methods and submitted as overview documentation outlining the existing control and electrical systems, equipment locations and take-over points.

Project Execution Plan

Submitted as a general plan developed for larger scope projects, a System Wide Design Specification is Submitted as an overview document outlining the project scope, control system overview, HMI, design concepts, control strategies and design standards.

First Engineering Submittal (FES)

The FES is submitted as a basic design document that includes a description of operation, I/O requirements, and preliminary equipment designs. It consists of a functional description (from an operator’s perspective), preliminary HMI screens, design standards, equipment lists, and arrangement drawings.

Second Engineering Submittal (SES)

The SES is called the “Detailed Design” and describes the system in specific terms, including a software organization chart and task/program/routine descriptions for all sub-systems. The project’s functional requirements (as introduced in the FES) are finalized, and control techniques are described in sufficient detail to allow software coding to begin.

Design Specification

The documentation specifies all communications within the control system; it defines all data exchanges between sub-systems, including network type, the mechanism (Ethernet, etc.), update rate (message-based or cyclical), and signal descriptions, including tag names and units. A preliminary version is submitted with the FES that includes basic definitions of the interfaces; comprehensive details are submitted with the SES, including spreadsheets that list all signals. Equipment Design I/O and equipment lists are used to develop arrangement drawings of all system components. Customer involvement is encouraged in designing the more subjective components, such as operator control stations. Electrical schematics are customized toad here with customer standards.

Level 2 Software and Models

Level 2 provides mathematical process models and the required software to function. Level 2 distributes references to the level 1 controllers and receives process feedback for model updates and data collection. FLANDERS has unique experience in migrating and upgrading older legacy platforms and converting to new windows based on open operating systems. This approach helps you stay ahead of the curve with automation obsolescence.

Network communications for Remote I/O are based on the Ethernet/IP protocol or an equivalent common industrial networking platform configured as a redundant device-level ring. Communications bridges between legacy and modern network protocols allow the integration of new drives and controllers until the system is completely replaced and the legacy platforms are entirely removed. After the system replacements, the purchaser will be left with a fully supported industrial communications infrastructure. Our domain expertise and a deep understanding of the networks and data structures will allow for an optimal implementation strategy throughout the project.

A Siemens Solution Partner

We are a Siemens Solution Partner and Distributor for industrial control products, including PLC, HMI, VFD, and motors. We are authorized to develop solutions, implement technologies, and repair systems that carry the Siemens warranty.

ABB systems integration

We’re an Authorized System Integrator for ABB low voltage AC/DC drives and PLCs for industrial machines and are recognized as a distributor for ABB/Baldor motors.

Rockwell Automation

A Rockwell Systems Integrator, FLANDERS develops solutions using Allen-Bradley ControlLogix™, CompactLogix™, and PowerFlex drives. We also upgrade outdated PLC-5 and SLC systems.

We consider ourselves an extension of our customer’s maintenance and engineering staff. FLANDERS field engineering will partner with your support staff to train, service, optimize, or upgrade your control systems for better efficiency and reliability of your process. Flanders offers 24/7 availability or embedded/remote support to keep your lines running.