Custom Vendor-Independent SCADA/HMI Software to Replace Siemens WinCC for ~30-Axis Kinetic Canopy

@Herculesz

Hi I have strong experience with industrial HMI/SCADA-style applications, Siemens S7 communication, Snap7-class PLC integration, PostgreSQL, InfluxDB, WebSockets, WebGL dashboards, audit logs, TOTP authentication, and production deployment on industrial PCs. The main technical challenge is replacing the WinCC supervisory layer while keeping the certified S7-300F PLC as the safety authority and never moving hard interlocks into the web application. My approach would start with a requirements and tag-map discovery phase, defining read/write boundaries, mirror DB structure, command handshakes, heartbeat behavior, and safe link-loss handling. For the PLC driver, I would build a cyclic acquisition layer with reconnect logic, timestamped tag validation, alarm state handling, and deterministic command confirmation. For the operator dashboard, I can deliver a responsive web HMI with live 2D axis state, 3D WebGL canopy visualization, alarm/event history, audit logs, reporting, backups, and role-based access. Weather supervision would be modeled as a clear state machine for normal, elevated, high wind, and sensor-loss conditions, with retract-only and auto-retract behavior driven by PLC-approved commands. I can provide full source code, reproducible builds, SBOM, FAT/SAT documents, operator manuals, and warranty-ready support procedures. I am comfortable working under NDA and can share relevant industrial automation references privately. Thanks, Hercules

@Mahihassi

I understand the critical importance of developing a custom, vendor-independent SCADA/HMI software application such as outlined in your project brief. As an electrical engineer specializing in firmware development and IoT product engineering, I have a proficiency in working with industrial automation systems and bespoke firmware solutions. My extensive hands-on expertise with Siemens S7 series PLCs, communication protocols such as S7 and Profinet, and familiarity with the snap7-class library make me well-versed for this particular project. I assure you a smooth transition to my proposed online / web-based software solution. Apart from my solid technical grounding, I prioritize the broader aspects of your project. By adhering to your time-tested system architecture and requirements/discovery process, I can ensure robust communication capabilities (even during link-loss), dependable wind/weather monitoring logic, meticulous alarm/event management routines, comprehensive user management controls, and timely automated reporting for you. My scope extends beyond mere functional deliverables as well. With full stack competencies including web and mobile app development plus experience in PostgreSQL, InfluxDB for data storage & backup; WebSocket for real-time updates; Two-factor authentication (TOTP) implementation; and multi-lingual support (including RTL), rest assured I can provide handy add-ons if need be. Best, sardar (ceo MHTechFusion)

@trm66614

I deliver a vendor‑independent SCADA/HMI that runs on the existing industrial PC and talks to the PLC over Ethernet with robust, mirrored tag data. A PostgreSQL historian stores tag history, events and audits, with monthly PDF reporting and on-demand export. The architecture emphasizes Software Architecture discipline, keeping safety boundaries between PLC interlocks and software control intact. The stack leverages Node.js for the backend and real‑time WebSocket updates, while the front end can use React Native for tablet-ready dashboards; if needed, a web UI is also fine. Targeted skills integration: MySQL can back optional data loads, while PostgreSQL handles the main data store; the design supports scalable data pipelines. The solution will include full source code, an SBOM, reproducible builds, FAT/SAT plans, and a 24‑month warranty with multi-tier support. How will you guarantee safe, deterministic multi-axis coordination (~30 axes) with PLC link loss and automatic reconnection while preserving the safety boundary between PLC interlocks and software control? With this approach you get a robust, scalable, and maintainable platform that reduces risk and accelerates deployment in complex multi-axis environments.

@OscarMozo

Hi, I can help you with this. I am a developer with extensive experience with automations and integrations. I've helped clients with similar projects. Let me know your interest, Sincerely, Nicolas

@mahig47

Hello! As per your project post, you are looking to replace the existing Siemens WinCC supervisory layer with a vendor independent SCADA/HMI platform for a large scale kinetic retractable canopy system comprising approximately 30 independently controlled axes. The goal is to develop a robust software only solution that integrates with the existing Siemens S7 PLC infrastructure . My focus will be on delivering a scalable SCADA/HMI platform featuring reliable S7 PLC communication, cyclic data acquisition, automatic reconnection handling, real time supervisory control modes, weather driven operational logic, alarm and event management, audit logging, user role management with 2FA, historian integration, automated reporting, WebSocket based live updates, and responsive operator dashboards with both 2D and 3D canopy visualization. I specialize in industrial automation platforms, SCADA systems, real time monitoring applications, IoT architectures, and mission critical operational software. My approach focuses on reliability, maintainability, cybersecurity, and long term vendor independence while ensuring seamless integration with existing industrial infrastructure. Let’s connect to review the current architecture, PLC interfaces, and operational workflows so we can design a reliable and future proof SCADA/HMI replacement platform. Best regards, Nikita Gupta.

@kishanbwts

I’ve worked on replacing Siemens WinCC layers with custom SCADA software linked to S7-300/400 PLCs using the snap7 library. For tag mapping, I start by reading live PLC data blocks, cross-checking tags with PLC documentation and on-site data traces to ensure accuracy before committing to the control logic. In a recent project controlling multi-axis motion on factory conveyors, supervisory software ran parallel to a certified fail-safe PLC without changing its safety code. The software handled monitoring, alarms, and commands strictly outside the safety interlocks, ensuring no safety risk on communication loss by defaulting to safe PLC states. For 30-axis coordinated motion control, I implement state machines reflecting each mode (sequential, parallel, patterns) and use watchdog timers plus PLC link loss detection to halt motions safely. Weather-based retract logic has been implemented before using serial RS-485 data inputs processed alongside Ethernet PLC data, triggering automatic retracts on threshold breaches. To achieve real-time WebSocket dashboards, I decouple data acquisition and UI rendering, use efficient JSON diffing, and optimize 3D WebGL models for low-resource tablet browsers. I deliver full source with reproducible builds, SBOMs, and offer 24-month warranty support including priority support tiers. I’m ready to travel to the Gulf region with expenses reimbursed. Does your current S7 tag map include a designated “mirror” data block for non-optimized cyclic access, or will that require setup in the discovery phase? Would you prefer a desktop Electron app or a purely browser-based interface for the operator dashboard? I can start defining architecture and milestone breakdowns as soon as you share the NDA and detailed requirements.

@mayr81

Hi, I can help you design and build a full custom SCADA / HMI replacement system for your Siemens S7-300 PLC environment, including real-time monitoring, supervisory control, and a modern web-based operator dashboard. I will build a vendor-independent application that communicates with your PLC over S7 protocol using a stable industrial-grade library, ensuring safe, reliable tag mapping and continuous data acquisition. The system will fully respect the safety boundary, meaning all critical interlocks remain inside the PLC, while the software layer handles monitoring, operator commands, alerts, and visualization. The solution will include a real-time control dashboard (2D + optional 3D WebGL view), alarm management, weather-based safety logic, user roles with 2FA, audit logs, and full historical data storage using PostgreSQL + time-series database. I will also ensure fast real-time updates using WebSockets (~100ms target). All modes like open/close patterns, emergency retract, and multi-axis coordination (~30 axes) will be implemented with safe fallback behavior on PLC disconnect and automatic reconnection logic.