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Practical technical guides, calculation examples and checklists on automation, electronics, machinery, technical service and software.
24 articles
An old machine: retrofit or new investment?
Retrofit or new machine? A guide that turns the investment decision into something concrete, using mechanical capability, scope uncertainty, downtime cost, safety and the changeover plan.
Watchdog, brown-out and safe fault handling in embedded systems
Resetting a device is not the same as recovering it safely. Task health, brown-out, data integrity and output behaviour after a reset.
Secure remote access to machines: balancing rapid support and cybersecurity
Setting up remote service access in a controlled and traceable way: network segmentation, least privilege, time-limited sessions, backups and connection-loss scenarios.
Tackling interference in the field: grounding, shielded cable and cable segregation
To find the path along which interference travels, examine cable segregation, chassis and signal reference together. Why is there no single general recipe for shield termination?
Switch-mode power supply (SMPS) faults: symptoms and diagnosis
Separate the load and the distribution line before replacing the power supply. No-load/on-load behaviour, inrush current, measurement point and post-repair acceptance checks.
Servo or stepper motor? Choosing the right drive for custom machinery
Motor resolution is not actual axis accuracy. A servo/stepper comparison based on the torque-speed curve, inertia, feedback, microstepping and mechanical transmission.
Inductive, capacitive or photoelectric: choosing the right industrial sensor
To select the right sensor, assess the complete chain from target material to PLC input. Sensing margin, output type, speed calculations and tests with actual samples.
8 criteria to consider when choosing a PLC for a new machine
Look beyond I/O count when choosing a PLC: eight criteria covering end-to-end response, communication load, memory, environment, safety and maintenance cost.
Why is documentation in PLC programs not a luxury?
How do you prepare a PLC handover package that the maintenance team can actually use? Symbols, I/O list, state flow, backups, rollback and change logs.
PID tuning in heating systems: how do we reduce overshoot in the field?
Reduce temperature overshoot by reading the process response, not by changing parameters at random. Integral windup, ramping, the output element and comparative tests.
Noise, grounding and EMC in industrial PCB design
Return current, switching loops, decoupling and connector protection for a PCB that runs stably in the field. Points to watch during measurement and prototype testing.
Control-panel thermal management: choosing fans, filters and cooling units
When is a fan sufficient, and when is a cooling unit required? A selection approach based on heat dissipation, ambient temperature, an example airflow calculation, airflow paths and condensation.
6 points to watch in a control panel retrofit
In a control panel retrofit, the survey, protection, wiring, heat and changeover plan must be addressed together. A six-step approach that preserves functions and is verified by testing.
Common mistakes when creating a preventive maintenance plan
Moving from a list that fills a calendar to a maintenance plan that delivers results: equipment criticality, comparable measurements, actionable work orders and trends.
Making production data visible: starting with OEE in small steps
Start collecting reliable production data with a single machine. The three components of OEE, with a time model, counter verification and a sample shift calculation.
Modbus RTU and TCP communication problems: step-by-step troubleshooting
Is there no response, or is the returned value wrong? A diagnostic guide covering RTU/TCP layers, register offset, data type, word order and polling load.
Electronic board design for humid and marine environments
Is coating the board on its own enough to protect against humidity, salt, condensation and vibration? We look at the enclosure, connectors, surface preparation and environmental verification together.
An introduction to machine safety: emergency stop, safety relay and performance level
Safety beyond the emergency stop: the relationship between risk assessment, the safety function, PLr, final elements and validation of the installed system.
Liquid exposure and corrosion on electronic boards: is repair possible?
What should be assessed before re-energising a liquid-damaged board? Damage mapping, material-appropriate cleaning, data protection and functional verification.
Capacitor ageing in drive and control boards: a silent cause of failure
Why is a capacitance measurement not enough on its own? Points to consider regarding ESR, ripple current, temperature, lifetime estimation and selecting an equivalent part.
Commissioning a frequency inverter: key parameters and common mistakes
A commissioning process that starts with the motor nameplate and extends to a real load test: command sources, control mode, ramps, braking and parameter backups.
7 rules for designing operator-focused HMI screens
Screens that help the operator make the right decision: information hierarchy, alarm language, command feedback, trends and task-based acceptance tests.
HMI panel will not start: a first checklist before calling for service
A black screen, restarts and frozen values are not the same fault. A checking approach that separates power, software and communication while protecting the device's data.
Industrial monitoring with ESP32: where to use it and where not to
How do we manage field signals, connection outages and data quality when collecting data with an ESP32? The boundaries between monitoring and control, and a pilot test plan.
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