PLC rack & I/O modules
Power supply, CPU and I/O modules on a DIN rail, with LEDs following the scan cycle.
Engineering Service
Automation & Custom Control Work
Custom control boxes and operator panels, an ESD workstation monitor, counter stations and sensor alarm boxes, plus control-box wiring and modification.
Overview
Service introduction
Not every requirement is a repair. Production lines often need a control box modified, a simple custom controller built, or a counter or display added.
Our past builds include a smart ESD workstation monitor that only powers the station once the operator's wrist strap checks OK, the operator control panel for a modified excavator, with speed adjustment and an emergency stop, a counter station with one counter per inspection category, a humidity control box with three humidity meters, a timer and an alarm, a wall-mounted temperature and humidity alarm display with an external probe and a strobe siren, and a five-sensor alarm box.
We take on practical control and electronics work for agreed applications — circuit changes, connector replacement and wiring repairs — with the technical scope confirmed for each enquiry.
Technical capabilities
- Sensor-based monitoring and interlocks that switch an output and raise an alarm
- Operator control panels: start / stop, direction, speed adjustment and emergency stop
- Counter stations with one counter per category
- Custom humidity control boxes with set-point meters, timer and alarm
- Room temperature and humidity monitoring on a large LED display, with upper and lower alarm limits
- Sensor alarm boxes with indicator lamps and buzzer
- Control-box wiring and modification
- Circuit changes, connector replacement and wiring repairs
Past projects
Control boxes and panels we have built
A selection of custom builds from our workshop. Customer names and sites are not shown.
Illustrative 3D model drawn in code to explain how the build works. Not a photograph.
Sensing & interlock
Smart ESD workstation monitor
A workstation interlock that only switches on power to an ESD station once the seated operator's wrist strap checks OK.
- Senses when an operator sits down; with the seat empty all three lamps are off and station power is off
- Amber lamp and a 5-second check for a correctly worn ESD wrist strap
- Strap OK: green lamp and station power on
- Strap faulty or not worn: red lamp, buzzer, and power stays off
- Leaving the seat clears the state; sitting down again restarts the full 5-second check
- PC dashboard shows the station state; check delay, sensitivity and detection distance are set to the customer's SOP
Illustrative 3D model drawn in code to explain how the build works. Not a photograph.
Control panel
Operator control panel
The control system for a modified wheeled excavator: a push-button panel in an IP56 enclosure that runs the drive and the augers on the left and right of the machine, which screw into the ground to hold it in place while it works.
- Forward, reverse and 4-wheel-drive selection
- Left and right auger controls with start and stop buttons
- Five speed-adjust knobs
- Emergency stop
Photo of the finished build Illustrative 3D model drawn in code to explain how the build works. Not a photograph.
Counter project
Inspection counter station
A stainless-steel counter station where each push button adds one to its own counter, so an operator can tally results by category.
- Twelve Omron H7EC counters on the front panel
- One labelled button per category, such as scratches, chip, crack, corrosion and contamination
- Reset button and front power switch
Photo of the finished build Illustrative 3D model drawn in code to explain how the build works. Not a photograph.
Monitoring & alarm
Custom humidity control box
A control box for a wafer fab with three digital humidity meters and a digital timer, wired to external humidity sensors and fitted with a local alarm.
- Three humidity set-point meters (Meter 1 to 3, reading in %) and a digital timer
- Red beacon and buzzer for the alarm
- Output connection and cabled sensor leads
Photo of the finished build Illustrative 3D model drawn in code to explain how the build works. Not a photograph.
Room monitoring & alarm
Temperature & humidity alarm display
Installed at a customer's request to watch the temperature and humidity of a room: a large LED display mounted high on the wall, with an external probe and a strobe siren, and upper and lower limits set for both readings.
- Large red LED display showing the room's temperature (°C) and relative humidity (%) at a glance
- External temperature and humidity probe, mounted on the cable trunking away from the display
- Upper and lower alarm limits set for temperature and for humidity to suit the room
- Red strobe siren comes on when either reading goes above its upper limit or below its lower limit
- Mounted on the wall just under the ceiling, with the cables run in PVC trunking and power from a nearby socket
Photo of the finished build Illustrative 3D model drawn in code to explain how the build works. Not a photograph.
Push-button control box
Five-sensor alarm box
A push-button control box for a wafer fab that watches five sensors, with a red indicator for each sensor and a buzzer for the alarm.
- Five red indicator lamps and a green push button
- Buzzer on the side of the enclosure
- Labelled plug-in sensor leads through cable glands
- Mains supply through a fused 13 A plug
Photo of the finished build
In 3D
The equipment behind this service
Illustrative models drawn in code. Not photographs of customer equipment or of a specific product.
Applicable equipment and common faults
Applicable equipment
What we work on
- Control boxes
- Operator control panels
- Counter / display units
- Set-point meters & timers
- Temperature & humidity displays
- Sensor alarm boxes
- Wiring & interfaces
Send the brand, model and part number with photographs, and we will review whether the unit is within our repair scope.
Typical faults
Symptoms we assess
- Control box needs modification for a new process
- Damaged or unreliable wiring and connectors
- Need for a simple custom control, monitoring or push-button box
- Production or inspection counts need a counter or display
- Sensors need a local alarm with lamps and a buzzer
- Workstation power should depend on an operator or ESD wrist-strap check
Engineering process
Our workflow for this service
- STEP 01
Understand
Discuss the application, the required function and constraints.
- STEP 02
Diagnose
Assess the existing setup, wiring and parts involved.
- STEP 03
Agree
Confirm technical scope, deliverables and quotation.
- STEP 04
Build / modify
Carry out the approved wiring, circuit or build work.
- STEP 05
Verify
Record the applicable functional checks and hand over.
Verification depends on the equipment and available test conditions. Workshop checks are distinguished from testing that requires your machine, program or production setup.
Request for Quotation
Request a quotation: Automation & Custom Control Work
Share the manufacturer, model or part number, quantity and the fault you are seeing. Photos or documents help us assess the job faster.