Next-Gen Modular Control System for Diverse Industrial and Chemical Applications
Overview
The client needed a modular, configurable, and scalable I/O and communication platform to support diverse chemical automation use cases, ensuring flexibility, seamless connectivity, and compliance with industry standards
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Challenges
Lack of a flexible, modular I/O and communication system to support multiple automation use cases
Difficulty in ensuring seamless connectivity and compliance with stringent EMC, safety, and environmental standards
Solution
- Conducted discovery workshops to define subsystems, connectivity & application use cases
- Designed a configurable power card with rail sequencing, protections, and telemetry for I/O & comm modules
- Built an expandable backplane I/O architecture with slot addressing, diagnostics & defined power/data planes
- Developed configurable I/O (DI/DO/AI/AO/RTD/TC) with per-channel isolation, range programming & health monitoring
- Developed a secure, redundant multi-protocol gateway supporting PROFINET, EtherNet/IP, Modbus, and CAN
- Performed automated V&V testing (functional, regression, fault injection) with EoL fixtures
- Ensured EMC, safety, and environmental compliance with certification-ready docs
Outcomes
- Reduced operational costs by 15-18% and lowered maintenance efforts by 25-30% through modular, scalable architecture with built-in diagnostics
- Improved efficiency and faster time-to-market with seamless multi-protocol connectivity and compliance-ready design
