NOTICE:

Please note that this repo is strictly a prototype that will probably not be maintained. You are welcome to work on this if you like, just make a fork and do your own thing.

🤖 Studio 5000 AI-Powered PLC Programming Assistant

This revolutionary MCP (Model Context Protocol) server transforms PLC programming by providing AI-powered code generation, L5X routine creation, real .ACD file generation, and seamless Studio 5000 integration. Convert natural language specifications directly into working ladder logic and complete Studio 5000 projects!

⚡ TL;DR - For Impatient Teammates

# 1. Get Python 3.12 (NOT 3.11!) from python.org
python --version  # Must show 3.12.x

# 2. Clone and install
git clone <repository-url>
cd Studio5000_MCP_Server
pip install -r requirements.txt

# 3. Install SDK (CRITICAL for .ACD files!)
pip install "C:\Users\Public\Documents\Studio 5000\Logix Designer SDK\python\logix_designer_sdk-*-py3-none-any.whl"

# 4. Test it works
python src/mcp_server/studio5000_mcp_server.py --test

That's it! ✅ Skip to Claude Desktop setup if tests pass.

📚 New Team Member Resources

🎯 Complete Team Guides Available:

• 📖 TEAM_USAGE_GUIDE.md - Complete workflow guide with real examples
• ⚡ QUICK_REFERENCE_CARD.md - Daily commands and shortcuts
• 🔧 TEAM_TROUBLESHOOTING_GUIDE.md - Common issues and solutions

🚀 Quick Start for Teammates

Ready to use this tool? Follow these steps:

Prerequisites ⚠️ CRITICAL

• Python 3.12 (NOT 3.11 or earlier - the SDK will not work!)
• Studio 5000 Logix Designer v36 or later installed on your machine
• Windows Operating System (Studio 5000 SDK is Windows-only)

Installation Steps

1. Verify Python 3.12:

   python --version
   # Must show Python 3.12.x - if not, install Python 3.12 from python.org
   

2. Clone and Install:

   git clone <repository-url>
   cd Studio5000_MCP_Server
   pip install -r requirements.txt
   

3. Install Studio 5000 SDK (for .ACD files):

   pip install "C:\Users\Public\Documents\Studio 5000\Logix Designer SDK\python\logix_designer_sdk-*-py3-none-any.whl"
   

4. Test the Installation:

   python src/mcp_server/studio5000_mcp_server.py --test
   

   ✅ Should show: Documentation indexed, SDK available, tests passing

5. Ready to Use! - The server will auto-detect your Studio 5000 installation paths

Having Issues? See the Troubleshooting section below.

🚀 AI-Powered Features

🧠 Natural Language to PLC Code

• AI Code Generation: Convert plain English to working ladder logic
  • "Start the motor when the start button is pressed and stop it when the stop button is pressed" → Complete ladder logic with proper start/stop interlocking
• Smart Pattern Recognition: Automatically detects start/stop, timer, counter, and basic I/O patterns
• Intelligent Tag Creation: Automatically generates appropriate I/O tags with descriptive names
• Instruction Validation: Validates generated code against official Studio 5000 documentation database

📁 L5X Project Generation

• Project Structure Creation: Generates L5X project files with programs, routines, and tags (can create routines to be imported into existing projects and can create empty l5x files to be manually developed)
• Multiple Controller Support: Support for various Allen-Bradley controllers (1756-L83E, 1756-L85E, etc.)
• ⚠️ Current Limitation: Generated L5X files may have RLL formatting issues requiring manual fixes
• Structured Output: XML structure follows Studio 5000 schema but may need validation
• 💡 Best Practice: Use for project templates, then add logic manually in Studio 5000

🏭 Real .ACD Project Creation

• Official Studio 5000 SDK Integration: Creates genuine .ACD files using Rockwell's official SDK
• Direct Studio 5000 Compatibility: .ACD files open directly in Studio 5000 without conversion
• ✅ Empty Project Creation: Clean ACD templates ready for manual development (RELIABLE)
• ⚠️ Complete Project Creation: Experimental - SDK partial import for MainProgram/MainTask (UNRELIABLE)
• Version Control: Supports different Studio 5000 major revisions (v36 default)
• 💡 Recommended: Use empty ACD creation + manual L5X import workflow

🔍 Vector-Powered Semantic Search

• Intelligent L5X Analysis: Semantic search through massive L5X files (tested with 49k+ lines)
• Production-Scale Processing: Handles complex industrial automation projects
• Smart Code Insertion: AI finds optimal positions for new logic in existing routines
• Dependency Analysis: Automatic detection of component relationships and dependencies
• Pattern Recognition: Understands conveyor control, encoder logic, fault handling, and timer patterns
• FAISS Vector Database: Lightning-fast semantic search with embedding-based similarity

📐 Technical Drawing Analysis

• PDF Engineering Drawings: Extract and search through technical drawings (P&IDs, electrical schematics, control logic diagrams)
• AutoCAD Integration: Parse CAD-generated PDFs with rich text and vector graphics content
• Equipment Context: Automatically find drawings referenced by equipment tags and system components
• Vision AI Enhancement: Advanced analysis of complex technical diagrams and equipment connections
• Cross-Reference Capability: Link drawings with existing L5X code and tag databases for complete system understanding

📊 Advanced L5X Analysis System

• Real Production Testing: Verified with actual 2.9MB L5X files from industrial systems
• Complexity Scoring: Automatic assessment of routine complexity and refactoring needs
• Component Mapping: Tracks timers, counters, tags, and their interconnections
• Surgical Modifications: Precise rung insertion without disrupting existing logic
• Professional Workflow: Read-only analysis with SDK-powered modification capabilities

📚 Documentation Access

• Comprehensive Instruction Database: Searches through official Studio 5000 documentation
• Smart Search: Find PLC instructions by name, description, category, or functionality
• Detailed Information: Get comprehensive details about instruction syntax, parameters, and usage
• Category Browsing: Browse instructions by functional categories (Alarm, Math, Motion, Timer, etc.)
• Language Support: Information about which programming languages support each instruction (Ladder, ST, FBD)
• Real-time Validation: Instant validation using official Rockwell documentation

📋 Detailed Installation Guide

Prerequisites - READ THIS FIRST! ⚠️

🚨 CRITICAL REQUIREMENT: Python 3.12 ONLY

• This project REQUIRES Python 3.12 - earlier versions will fail
• Studio 5000 SDK is incompatible with Python 3.11 and earlier
• Verify your Python version FIRST before proceeding

System Requirements:

• Python 3.12.x (Download from python.org)
• Studio 5000 Logix Designer v36 or later installed
• Windows Operating System (Studio 5000 SDK is Windows-only)
• Administrator privileges may be required for initial setup

Step-by-Step Setup

Step 1: Install Python 3.12

1. Download: Go to python.org and download Python 3.12
2. Install: During installation, CHECK "Add Python to PATH" ✅
3. Verify: Open Command Prompt and run:

   python --version
   # Must show: Python 3.12.x (if not, restart command prompt)
   

Step 2: Get the Project

1. Clone the repository:

   git clone <repository-url>
   cd Studio5000_MCP_Server
   

Step 3: Install Dependencies (CRITICAL!)

1. Install all required packages:

   pip install -r requirements.txt
   

   This installs:

   • Core Components: BeautifulSoup, XML processing, async support
   • AI & Vector Search: PyTorch, sentence-transformers, FAISS vector database
   • Semantic Analysis: Vector embeddings for instruction and L5X search
   • Performance: Optimized versions for production use

   If you get errors, try:

   python -m pip install --upgrade pip
   pip install -r requirements.txt
   

   Note: Vector database components (torch, sentence-transformers, faiss-cpu) are included for semantic search capabilities. These enable advanced L5X analysis and instruction search features.

Step 3.5: Install Studio 5000 SDK (CRITICAL for .ACD files!) 🚨

⚠️ TEAMMATES MUST DO THIS STEP - Skip only if you don't need .ACD file creation

1. Find the SDK wheel file in your Studio 5000 installation:

   # Look for this file (version may vary):
   dir "C:\Users\Public\Documents\Studio 5000\Logix Designer SDK\python\logix_designer_sdk-*-py3-none-any.whl"
   

2. Install the SDK wheel file:

   # Replace with your actual file path and version:
   pip install "C:\Users\Public\Documents\Studio 5000\Logix Designer SDK\python\logix_designer_sdk-2.0.1-py3-none-any.whl"
   

3. Alternative - if you can't find the wheel file:

   # Navigate to the SDK directory and install from there:
   cd "C:\Users\Public\Documents\Studio 5000\Logix Designer SDK\python"
   pip install logix_designer_sdk-*-py3-none-any.whl
   

Without this step: Documentation and L5X generation will work, but .ACD file creation will fail!

Step 4: Test Your Installation ✅

1. Run the test command:

   python src/mcp_server/studio5000_mcp_server.py --test
   

2. You should see:

   • ✅ "Documentation indexed successfully" (500+ instructions found)
   • ✅ "SDK Available: True" (if you installed the SDK wheel file correctly)
   • ✅ "SDK Available: False" (OK if you skipped SDK installation - L5X generation still works)
   • ✅ Sample search results and code generation tests

3. If SDK Available shows False but you installed the wheel file:

   • Check the wheel file path was correct
   • Try: python -c "import logix_designer_sdk; print('SDK OK')"

4. If tests fail completely, check the Troubleshooting section

🎉 You're Ready to Use the Tool! 🎉

The server will automatically detect your Studio 5000 installation paths. Skip to the Configuration for Claude Desktop section to start using it!

---

Step 5: Configure Environment Variables (Advanced Users Only)

⚠️ SKIP THIS STEP - Only needed if Studio 5000 is installed in non-standard locations

Option A: Set via Windows Environment Variables

• Open System Properties → Environment Variables
• Add these User or System variables:

  STUDIO5000_DOC_PATH=C:\Program Files (x86)\Rockwell Software\Studio 5000\Logix Designer\ENU\v36\Bin\Help\ENU\rs5000
  STUDIO5000_SDK_PATH=C:\Users\Public\Documents\Studio 5000\Logix Designer SDK\python
  PYTHON312_PATH=C:\Users\YourUsername\AppData\Local\Programs\Python\Python312\python.exe
  

Option B: Create .env file (in project root):

STUDIO5000_DOC_PATH=C:\Program Files (x86)\Rockwell Software\Studio 5000\Logix Designer\ENU\v36\Bin\Help\ENU\rs5000
STUDIO5000_SDK_PATH=C:\Users\Public\Documents\Studio 5000\Logix Designer SDK\python
PYTHON312_PATH=C:\Users\YourUsername\AppData\Local\Programs\Python\Python312\python.exe

4. Find Your Studio 5000 Paths:

   Documentation Path: Look for this file in your Studio 5000 installation:

   <Studio5000_Install>\Logix Designer\ENU\v36\Bin\Help\ENU\rs5000\17691.htm
   

   Common locations:

   • `C:\Program Files (x86)\Rockwell Software\Studio 5000\Logix Designer\ENU\v36\Bin\Help\