From PLC Logic to Intelligent Systems: 6-Axis Robot and Vision Control with High-Level Programming

Context & background

CTRL Engineering develops advanced automation and control solutions for industrial applications, including custom testbenches and motion control systems. In industrial automation, Structured Text environments such as CODESYS or TwinCAT are widely used for reliable hardware interfacing. However, these environments often limit flexibility when implementing complex or scalable logic, and modern software concepts like object-oriented design and modular architectures remain difficult to apply efficiently.

As industrial systems grow in complexity, there is a clear need to explore hybrid programming approaches — keeping low-level hardware control in Structured Text while offloading higher-level logic to more expressive languages like C#. CTRL is eager to investigate how this shift can improve development efficiency, maintainability, and scalability without compromising real-time performance.

Thesis objective

The goal of this thesis is to explore and evaluate a hybrid automation architecture in which low-level hardware control remains in Structured Text while higher-level logic is implemented in C#. A demonstration system will be developed in both a purely Structured Text implementation and using the hybrid approach, and compared across dimensions such as development effort, flexibility, scalability, maintainability, and performance. The research will be conducted on the Bosch Rexroth ctrlX platform. As an extension, the approach may be applied to 6-axis robotic arm control and optionally to vision integration using HALCON in C#.

Research deliverables

• A technical research report evaluating hybrid PLC/high-level programming architectures and their applicability in industrial automation.
• A working demonstration system implemented in both pure Structured Text and the hybrid C#/ST architecture on the ctrlX platform.
• A structured comparative analysis covering development effort, flexibility, scalability, maintainability, and real-time performance.
• (Optional) An extension applying the hybrid architecture to 6-axis robot motion planning and synchronisation.
• (Optional) A vision integration proof-of-concept using HALCON in C#, evaluating reduced reliance on protocols such as OPC UA.

Research question examples

• “What are the practical benefits and trade-offs of implementing higher-level automation logic in C# compared to Structured Text?”
• “How can a hybrid PLC/C# architecture be structured to maintain real-time reliability while gaining the flexibility of object-oriented design?”
• “To what extent does combining vision and control logic in a single high-level language reduce system complexity in industrial automation?”

Student Profile

We are looking for a motivated student with a genuine interest in both industrial automation and modern software engineering. Relevant skills and interests include:

• Experience with PLC programming, preferably in Structured Text (CODESYS, TwinCAT, or similar)
• Knowledge of C# and object-oriented programming principles
• Interest in industrial robotics, motion control, or vision systems
• Curiosity about bridging the gap between traditional automation and modern software architecture
• Ability to work independently and communicate technical findings clearly

Speciality: PLC (ST), C#, OOP, (optional) vision — 1 or 2 student positions available depending on chosen extensions.

Interested?

We would love to hear from you! Please contact the dedicated CTRL contact person for this case. We can set up a meeting to get to know each other and discuss whether your wants and needs match ours.