Real definitions written for engineers who build machines — not marketers. Every term maps to a workflow step ClusterVise automates.
The complete hierarchical list of every component needed to build a machine — and a record of every design decision it contains.
Determining the exact channel count — DI, DO, AI, AO, safety, and high-speed counter — then selecting a PLC and expansion modules to match.
Matching drive output current, load type, duty cycle, braking, and fieldbus protocol — not just kilowatts — to the application.
Calculating total 24V DC demand across all panel and field consumers, with peak load, inrush, and temperature derating factored in.
Selecting the correct loop type — on/off, P, PID, cascade — and the analog resolution required to meet the process accuracy specification.
The end-to-end engineering workflow for custom machines — and why it is the most documentation-intensive workflow in industrial automation.
Sizing actuators, valves, flow controls, and air preparation units to meet cycle time while avoiding over-pressure and excessive air consumption.
Matching valve type (5/2, 3/2, 5/3), Cv, fail-safe behaviour, coil voltage, and manifold compatibility to each pneumatic actuator.
Calculating the bore diameter required to generate sufficient force at working pressure, with back-pressure correction and safety factors.
Matching peak torque, continuous torque, inertia ratio, feedback type, and fieldbus to the motion profile — not just motor nameplate kW.
The nine-document minimum set for a CE-marked machine — and why they drift out of sync with each revision when produced independently.
Designing E-stop loops, guard monitoring, and safety-rated I/O to meet EN ISO 13849 Performance Level requirements.
Choosing sensing technology, output type, range correction factors, and IP rating for each detection point on a machine.
Matching screen size, IP rating, processing capability, and communication protocol to the operator task and PLC ecosystem.
Calculating heat load from drives, PLCs, and PSUs to select the correct cooling method and prevent the leading cause of machine downtime.
Selecting the correct overload and short-circuit protection for DOL-started and VFD-fed motors — which are not the same device set.
Using remote I/O heads over PROFINET or EtherCAT to reduce field wiring on large machines — and the network design it requires.
Choosing between DOL, star-delta, and electronic soft starter based on motor power, load inertia, and starting current constraints.
What the Machine Directive 2006/42/EC actually requires — Technical File, risk assessment, harmonised standards, and Declaration of Conformity.
The EN ISO 12100 three-step method — and why doing it at the end of the project instead of the beginning is both a compliance failure and a design failure.
Arranging components inside an electrical enclosure to meet clearance rules, airflow requirements, and cable routing logic.
How the primary performance specification drives every component selection — and why sizing all actuators for minimum cycle time is a waste.
Selecting conductor cross-section, insulation class, and shielding based on current, installation method, voltage drop, and environment.
Choosing between standalone drives, PLC motion library, and dedicated motion controller based on synchronisation requirements and axis count.
Selecting fixed guards, interlocked guards, light curtains, or safety scanners based on hazard severity, access frequency, and safety distance.
Creating electrical circuit drawings that panel builders wire from, commissioning engineers test against, and maintenance teams use for fault-finding.
Sizing and arranging the electrical supply from incoming terminals through every protection device, contactor, drive, and 24V DC rail to the final field device load.
Designing, verifying, and documenting safety-related control functions that achieve a defined Performance Level (PLr) or Safety Integrity Level (SIL) under ISO 13849 / IEC 62061.
Choosing the right encoder type, resolution, interface protocol, and mounting for servo axes, conveyors, and rotary tables in special purpose machines.
Selecting PROFINET, EtherCAT, Modbus TCP, or other industrial networks based on PLC brand, cycle time, device ecosystem, and diagnostic requirements.
Selecting contactors by utilisation category (AC-1, AC-3, AC-4), frame size, coil voltage, and auxiliary contact requirements for motor and resistive load applications.
The structured process of verifying, testing, and proving every system on an industrial machine before production — covering FAT, SAT, loop checks, and safety validation.
Designing protective earth (PE) bonding and EMC grounding strategy for control panels with VFDs, servo drives, and distributed I/O — preventing faults and interference.
The IEC 61131-9 point-to-point communication standard that upgrades smart sensors and actuators from discrete signals to bidirectional digital communication over standard 3-wire cable.
Designing a compliant E-stop circuit with the correct stop category, Performance Level, safety relay architecture, and ISO 13849 documentation for CE certification.
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