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.

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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. 

Back view of aircraft mechnic repairing jet engine in a hangar.

Aerospace system


One of the few key players in manufacturing airplane components, was looking for a viable partner to develop software to control their test rigs. Thanks to our extensive experience in developing tailored software solutions for test rigs, DB Engineering was appointed as their preferred supplier. Nevertheless, the client imposed 4 stringent criteria the control system had to meet:

easy to use
flexible (user programmable)
built with industrial – readily available – components
upgradable via modem  

DB Engineering designed an automated programming system and implemented the full version of a 5000psi test rig control system. This comprised a high-speed data acquisition unit, redundant control and supervision touch panels. The entire operator interface was PC-controlled, while hydraulics were controlled by an industrial PLC-controller. Only worldwide available industrial components were used to build the control system.

The automated programming system was (and is) not only easy to use, but also allowed them to run its own CMM (Component Maintenance Manual) test programmes. The customer was so pleased with the outcome that it commissioned extra test rigs in the following years, including Overcentre, PTU, ECMP, EDP and many others.

Thanks to the flexibility of the DB Engineering systems, our software and control cabinets are now also being used by Delta Airlines, SAS (Scandinavian Airlines), RAM (Air Maroc), TAM (Brasil) and Air Canada