Industrial Automation Tools
Free resources built by engineers, for engineers. Convert data, troubleshoot systems, and level up your automation skills.
Tools
Free utilities built by engineers, for engineers. Solve real problems faster.
BitBench
Industrial Data Converter
64-bit base converter with PLC data types, Modbus CRC, IEEE 754 floats, and bit manipulation tools.
- Decimal, Hex, Binary, Octal, BCD conversions
- PLC data types (SINT, INT, DINT, REAL)
- Modbus register visualization
- Endianness byte swapping
GreenLight
ROI Calculator for Industrial Retrofits
Build the business case for your automation project. Calculate payback period, annual savings, and 10-year ROI projections.
- Downtime cost analysis
- Labor impact calculations
- 10-year cash flow forecast
- Shareable links & print reports
HotBox
Panel Power & Heat Calculator
Calculate total power draw and heat dissipation for control panel designs. Determine enclosure sizing based on thermal load.
- Component library (AB, Siemens, etc.)
- 24VDC & 120VAC load totals
- BTU heat load calculation
- Enclosure size recommendations
How-To Guides
Step-by-step guides for common industrial automation tasks
Reading Modbus Registers
Decode 32-bit floats from Modbus holding registers using proper byte order and data type conversions.
IO-Link Field Node Setup
Configure IFM AL1322 masters with CompactLogix processors. EDS setup, I/O mapping, and diagnostic troubleshooting.
FANUC Robot Backup Procedures
Create complete robot backups using a USB drive and the teach pendant. Image backups, program saves, and restore procedures.
Control Panel Basics
A plant manager's guide to PLCs, VFDs, safety components, power distribution, and networking inside industrial control panels.
Common PLC & Drive Fault Codes
Quick-reference fault code lookup for Allen-Bradley, Siemens, PowerFlex, and FANUC.
Preventive Maintenance Checklist
Practical PM checklist for PLCs, drives, robots, and panels. Daily, monthly, quarterly, and annual schedules.
Sinking vs Sourcing: I/O Wiring Explained
Understand sinking and sourcing I/O wiring for PLC digital inputs and outputs. When to use each and how to wire them correctly.
Frequently Asked Questions
Quick answers to common industrial automation questions
Endianness refers to the byte order used to store multi-byte data types in memory:
- Big Endian: Most significant byte first. Used by Motorola processors, TCP/IP protocols.
- Little Endian: Least significant byte first. Used by Intel processors, most PLCs.
When reading Modbus registers or communicating between systems, mismatched endianness causes values to appear corrupted. Use BitBench to visualize and convert between formats.
Modbus registers are 16-bit, so a 32-bit float spans two consecutive registers. The process:
- Read registers N and N+1 (e.g., 40001 and 40002)
- Combine based on byte order (usually CDAB or DCBA)
- Interpret the 32 bits as IEEE 754 single-precision float
Common byte orders: ABCD (big endian), DCBA (little endian), BADC (byte swap), CDAB (word swap).
Choose the smallest type that fits your data range:
- BOOL: On/off states, sensor inputs
- SINT (8-bit): -128 to 127 — Small counters, fault codes
- INT (16-bit): -32,768 to 32,767 — Analog inputs (raw), part counts
- DINT (32-bit): ±2.1 billion — Production totals, encoder positions
- REAL (32-bit float): Temperatures, pressures, analog values
Common causes of download faults:
- Memory mismatch: Project configured for different memory size than physical PLC
- I/O mismatch: Configured I/O doesn't match installed modules
- Firmware version: Program requires newer firmware than installed
- Keyswitch position: PLC in RUN mode instead of PROG or REM
Always verify your hardware configuration matches the physical setup before downloading.
Consider these factors:
- Parts availability: If replacement parts are discontinued, retrofit before a failure forces emergency action
- Downtime cost: Calculate hourly production loss. If a failure would cost $10K/hour, preventive retrofit is insurance
- Integration requirements: New systems often require modern protocols that legacy equipment can't support
- ROI timeline: Retrofits typically pay back in 12-24 months through improved efficiency
Our recommendation: If equipment is >15 years old with obsolete components, budget for retrofit within 2 years.
Need Help With Your Automation Project?
Our engineers have 25+ years of experience with Allen-Bradley, Siemens, FANUC, and more.
