Energy monitoring

Energy monitoring – development goals & energy efficiency


Our client is a recognized energy consultancy, specialized in energy monitoring for the industrial sector. 
They support companies in increasing their energy efficiency and saving energy costs.

The customer has developed its own software that can help companies by collecting their energy data to better understand their energy consumption. DB Engineering was commissioned to develop a platform that collects all data and implements it in our clients software program


  • Installation of various energy meters including Hardware Siemens Sentron: measures all data (energy values, consumption,…)
  • Placing a logger that collects all data and forwards it to the energy monitoring platform. These devices record energy values such as current and voltage and communicate them to a higher-level energy monitoring system for data analysis and evaluation. They will be able to record their power consumption with accurate time and cost details.
  • In addition to saving costs by optimizing consumption, they can also enjoy a more fail-safe system.
control system with analog pumpcontrollers

Upgrade 25MN Aluminium Extrusion press


DB Engineering was asked to make a major update of an old Allen Bradley PLC control system in an aluminium extrusion plant in Brisbane, Australia. Long time relations brought us in contact with this customer. During a visit back in September 2018, it was quickly decided that DB Engineering was the best partner to perform this job. Once the CAPEX was approved late 2019. The order was finally given and work could start! The actual startup is planned for April 2021.



  • The old control system (Allen Bradley SLC500) has to be replaced with a new Compact Logix System with a brand new program and HMI
  • The hardware was still working good, but software-wise a lot of optimizations were requested.
  • As the existing program was heavily modified over te years, the decisions was made to recreate a whole new program and HMI
  • At the sime time, the existing hydraulic components will also be screened (and replaced when obsolete) and the dead cycle time shortened.
If you would like more information, or if you have any questions don’t hesitate to contact us:
View of the existing control system with the analog pumpcontrollers
flying wheel generator

Rollercoaster generator


One of the top attractions at PLOPSA De Panne is operational again. End of last year, failure of the launch control generator caused the Anubis attraction to cease operation. 

As a long time partner for electrical repair services, DB Engineering was awarded the project to deliver and install a complete new 
1,4 MWatt generator. This generator is driven by a 160Kw drive added by a 4.8 Tons flywheelIts job is to deliver enough instantaneous power for the mind boggling launch of the carts 0.90km/h in just 2 seconds!

So, when the park hopefully opens soon, make sure ‘Anubis the ride’ is on your list!

Powered by DB Engineering


flying wheel generator
Motor flying wheel generator - Reconstruction

How a second hand machine became investment asset

make machine operational

Our client is known in the greenhouse construction sector. In addition to the classic glass greenhouses they also offer a wide range of foil tunnels for the professional gardener. They had acquired a saw machine but found out it dit not work due to failing electrics. 
DB Engineering accepted the challenge to figure out how the sawing machine operates. The assignment was to make the machine operational as soon as possible.


  • Installation of a new electrical cabinet with implementation of energy efficient components that avoids maintenance costs
  • New electrical wiring
  • Replacement of 230V hydraulic valves with 24VDC compressed air valves
  • Update command panels
  • Implementation of a Siemens 1500 CPU in Tia Portal together with a touch-sensitive TP 700 HMI screen which gives an operator an easy way to set-up the sawing machine.


By replacing the old components, they now know exactly which components are used. The machine is more user-friendly, faster and more reliable than before. Also the risk of incorrect cutting is less. By retaining the customers known working method, no additional training was required. Because of the implementation of the TP 700 HMI they have a level of traceability that was not achievable before. We did all this in less than a week. Mission accomplished!

If you would like more information, or if you have any questions don’t hesitate to contact us:


Aluminium Extrusion: Back to our origin


Our client is a global supplier of aluminum in 40 countries on all continents. DB Engineering was asked to retrofit a complete 3500 ton Aluminium Extrusion Line. The existing control systems, Multiprocessor Siemens Step5 and Cegelec PLC,  were withholding our customer to make the necessary optimizations to their production process.


DB Engineering was given the responsibility to:

  • Upgrade the control system and corresponding IO’s from Step5 to TIA-1500, making use of the most modern equipment available.
  • Replace obsolete serial RK512 and 3964R communications by ProfiNet
  • Reprogram PICOS System
  • Fully integrate HMI visualization and safety through PLC
  • Install SCALANCE wireless communication


The project is being executed in different phases, the first step being the Press control system.
The downtime during every phase will be minimized to reduce the pressure on the production targets.  Thanks to our optimizations the production process will run more efficiently.


Automation packaging line flower boxes

Our client is a major player in the horticulture sector and offers innovative packaging solutions. DB Engineering was consulted for a new ambitious project and adjusted their flower box packaging line process.

Due to speed differences on their production lines, the risk of damage to the flower boxes was too big. So we provided following solutions:

  • Each production line is managed with frequency controls so that the timing can be perfectly adjusted
  • A fully integrated automation system allowing them to control the packaging process via HMI screen.

Thanks to this succesful project, the customer has also decided to optimize their other production lines in a similar way in collaboration with DB Engineering!


Vertical form press


Our customer requested for DB Engineering to modernize the heart of the system, a limited fabricated and not supported electronic control system called MODAC. 

DB Engineering replaced all necessary electrical equiment (DC-motors, potentiometer controlled settings, PLC systems) with new modern entities including Siemens S7-1500 system with safety fully integrated, new Siemens Simotion Servo controlled motor for the material feed system, new HMI and Data Acquisition, future proof ERP communication.



Aluminium extrusion production line


Back in 1999, DB Engineering built the electrical control system of a complete Aluminium Extrusion Line in UK. That included everything, starting from the High Voltage 10kV transformer station, cabling all installed machines en designing all PLC programs. From Billet heater, over press, Puller, until the packing area.

The original PLC system, made by Schneider PREMIUM series, became obsolete after 20 years of perfect service. Since this platform is now end-of-life, DB Engineering was asked to come with a solution to ensure another 20 years of flawless production. 

Since DB Engineering has a lot of experience in refitting older extrusios presses, and is renowned for Schneider PLC systems. We were able to offer a complete new automation platform based on the new M580/M340 PLC platform of Schneider. All field networks will now be controlled by Ethernet.

For more information:    


Chino, CA, USA - May 3, 2015: Lockheed Martin F-22 Raptor stealth tactical fighter aircraft. View of compartment housing the electrical system at the Planes of Fame Airshow in Chino, California

Joint strike fighter


As part of the Joint Strike Fighter (JSF) – programme, The client was asked to develop a test rig for the JSF bomb door motor. Building further on earlier positive collaborations, the client called upon DB Engineering to help them realize this ambitious project.

The test rig was the first of its kind, as it had to control the bomb door motor with ultra-fast PIDs, in order to keep every movement under control. Knowing that a complete open/close – cycle of the doors only takes a few seconds, the control system needed to keep track of the position of the rotor at a speed of over 15.000 rpm, in order to guarantee correct test results.

DB Engineering installed a tailor-made control system with Dedicated Ream-time Controllers, PC-control with NI-modules and industrial PLC-controllers

Thanks to the control system with cycle times as low as 0.1ms, DB Engineering was able to succesfully meet the requested PATs (Product Acceptance Test)

Farnborough, United Kingdom - July 16, 2016: An Airbus A380 in flight

Airbus A380


DB Engineering was asked by Airbus to develop a control system for 2 hydraulic power packs to test the slats of the A380 Superjumbo. One power pack was running on normal mineral oil, whereas the second one was running on Skydrol (a highly sophisticated fl uid, mainly used on board airliners). The extreme deformations were induced by the mineral oil pack, whereas the Skydrol power pack controlled the wing’s inner systems, such as the flaps, slats and many other components. After completion of the basic control system, DB Engineering was also asked to connect the entire test area by network, allowing the Airbus engineers to modify several test parameters from their desks.

DB Engineering developed a control system, the design of which was not only very clear and comprehensive, but also very flexible. This allowed Airbus to change parameters fairly easy, while still receiving the necessary test results. To ensure the safety during the network operation, DB Engineering opted for a network structure, based on a combination of Ethernet, Profibus and ASI-safe. 

The test results gave Airbus a clear view on the long-term effects of stress loads on the entire wing structure and components and allowed them to detect possible failures (cracks) due to metal fatigue or composite failures. The specific network set-up significantly reduced the physical cabling, while maintaining safety, performance and flexibility.