Digitization of the Wire Drawing Process

We played a leading role in a £1 million project that successfully transitioned a customer’s wire drawing process into the digital space. Our team managed the entire software architecture design and code development, along with the design and implementation of the supporting database. Additionally, we developed and installed the network architecture, dashboards, HMI systems, PLC code, and handled protocol conversion.

This extensive project involved a variety of technical tasks, including Codesys PLC programming, S7-400 and S7-1200 PLC programming, Ubuntu server setup and configuration, network design and installation, Exor and Siemens HMI programming, Node.js application development, Python development, MySQL and Microsoft SQL Server development, as well as Arduino C code development.

Our contributions also encompassed designing, constructing, and installing six custom electrical control panels, setting up and calibrating 68 sensors, and installing specialized brackets and fixtures. We utilized Raspberry Pi devices as edge devices for dashboards and data collection, achieving over 800 data points and managing 238 I/O points. The project also included the installation of 37 current clamps, seven locally installed dashboards, one local server, one cloud server, and three IoT gateways—marking a transformative step in digitalizing the customer's manufacturing process.