How we troubleshoot

Evidence beats opinion

Most intermittent PLC problems get argued about for weeks because nobody was watching when they happened. We built our own read-only PLC recorder that turns "it just stops sometimes" into a timestamped record of exactly which signal changed, and when.

Two jobs, one tool

Troubleshooting

Finding intermittent faults

The recorder catches the exact moment a signal drops, so a problem that "only happens sometimes" gets a cause instead of a guess.

Loop tuning

Tuning loops with real data

The same recorder captures setpoint, process value, and output over real production runs. We use machine learning on that data to tune PIDs, instead of tweaking gains by feel and hoping it holds.

How we use it on a job

Start with the operator's words. A precise description of the symptom tells us where to look.
Trace the symptom through the logic. We follow every rung that can cause it, not just the tags with obvious names. The fault is usually in the part nobody suspected.
Record what lasts. A short pulse can slip between polls, so we also log counters and latched values that catch it. We write down what the recorder can't see, so a missing row is never read as "it didn't happen."
Confirm we're on the right PLC. Before trusting a single row, we check the controller against constants in its own program.
Read-only by design. The recorder can't write to your PLC at all, which is what lets us run it on a production line.
Only keep what matters. We log changes plus a snapshot before and after an event, not thousands of rows an hour.
Let it run through a real shift. Problems that won't show up in the lab show up in production.
Show the proof. The write-up points to the exact rungs involved, so your team can check it.

What it can't do

The recorder sees what the PLC sees, at the rate it checks. It won't catch a mechanical bind, a script running in the HMI, or a pulse faster than it checks, and every write-up says plainly what it could not see.

Got a problem nobody can pin down?

Tell us what the operators are seeing and we'll tell you how we'd catch it.