We designed, built and commissioned a perforator control system for a printing line — lifting and lowering the wheels on the moving web at precise positions, proven at production speed of 100 m/min.

When incubator temperature-control boards were no longer available, we reverse-engineered the originals, redesigned drop-in replacements, and calibrated each board in the workshop so onsite setup stayed fast and safe.

A set of Beckhoff AX51xx servo drives would not boot on the 24 V control supply. After repairing a recurring Schottky-diode fault, each drive was proven on a Beckhoff PLC over EtherCAT — TwinCAT scan, state machine to SAFE-OP — before return to the machine.

A print finisher was bringing in a new Kolbus perfect-binding line and needed three-phase power to the trimmer, gluer, binder, gatherer and blower. We worked out the loads, reused plant cable where it still fitted the ratings, ran new orange feeders from an existing sub-board, and powered the line up after testing.

Unidrive variable speed drives from Nidec (Control Techniques) are common across manufacturing and automation. When they fault, we diagnose and repair them at component level — tracing control, option-module and power-supply issues, then proving the drive on the bench so industrial equipment can return to service without a full replacement.

Lift and elevator control boards handle safety circuits, I/O and sensing throughout the system. When they fault, we diagnose and repair them at component level — restoring power rails, inputs and damaged connections so lift electronics can return to service without a full board replacement.

Vacon variable speed drives are widely used on manufacturing, pumping, conveyor and HVAC equipment. When they fault, we diagnose and repair them at component level — restoring control and power stages, then proving the drive on the bench so industrial motors can return to service without a full drive replacement.

SCADAPack 357E and 350E units are essential for industrial and utility data acquisition and control. When analogue readings drift or I/O fails, we diagnose and repair them at component level — then prove each unit on the bench so remote monitoring and control can return to reliable service without full replacement.

A Wohlenberg City 4000 gatherer would not start with the binder — then ran again without a clear fix. Checks on the Kuhnke I/O pointed at the start-position proximity input. The cause was a cracked M12 connector on the Bernstein sensor cable.

A blown fuse on a 160 kW Danfoss AquaDrive turned out to be a failed power stage — ruptured IGBT, shorted diodes and damaged gate-drive circuitry. We repaired the power card at component level, replaced an obsolete device from stock, and returned the drive to service.