Related to Obsolete Electronics Replacement & Redesign
Industrial control electronics: controller boards, interfaces and firmware for existing equipment
Micro Digital Engineering works on the electronics that controls existing industrial equipment: controller boards, input and output interfaces, their circuits and firmware, diagnostics of faults, modernisation and replacement of units that can no longer be sourced or repaired. The goal is to keep proven equipment working, with the signals, interfaces and behaviour it depends on agreed before design starts. We work on the control electronics inside the equipment; we do not supply plant automation, SCADA systems or control cabinets.
Discuss the control electronics
Confidential task? We sign an NDA before you share technical files.
Can you replace the controller board of a machine that is otherwise working well?
Yes. The signals, interfaces, timing and behaviour the machine depends on are defined first, together with what may change. The new controller board and its firmware are then developed to these requirements and verified on the bench and in the machine. Depending on the constraints, the replacement keeps the original form and connectors or takes a new form.
What the work covers
Controller boards
Replacement, modernisation or new development of controller boards for existing equipment, with available components and agreed compatibility.
Input and output interfaces
Digital and analogue inputs and outputs, drivers for actuators, isolation and protection, adapted to new sensors, actuators or signal levels.
Circuits and firmware
Schematic and PCB design of the control electronics, and controller firmware with its control, protection and diagnostic logic, typically on STM32 microcontrollers.
Communication with other equipment
Interfaces and protocol conversion between the controller and the equipment around it, as agreed for the project.
Diagnostics of faults
Investigation of failures, resets and unstable behaviour in existing control electronics, with the cause confirmed by measurement.
Modernisation and replacement
Keeping control units in service when their parts are obsolete: from analysis of the original to a verified replacement.
What this service is not
- Automation of production lines or plants, and integration of arbitrary industrial systems.
- SCADA or HMI system implementation, and PLC programming as a stand-alone service.
- Supply or wiring of control cabinets.
Our work is the electronics and firmware of the control units themselves.
How it differs from related pages
| Page | Main task |
|---|---|
| Industrial control electronics (this page) | Controller boards, interfaces, firmware and diagnostics of existing control units |
| Functional redesign of legacy electronics | A new electronic architecture that keeps the required functions |
| Industrial equipment telemetry | Measurements, diagnostics data and their transfer to existing systems |
| Obsolete electronics replacement | Choosing and implementing the replacement route for an obsolete unit |
How the result is verified
The control electronics is tested on the bench against the agreed requirements, including fault conditions, with measurements made with calibrated equipment, and then in the equipment under acceptance criteria agreed with you. Where an original unit is available, behaviour is compared with it under the same inputs.
PCB fabrication is performed by specialised manufacturing partners. Prototype component assembly, bring-up, debugging and verification are carried out in-house by our engineering team.
What you receive
| Deliverable | Format | How it is checked |
|---|---|---|
| Requirements | Document: signals, interfaces, behaviour, fault reactions, permitted changes | Review and written approval |
| Schematics, PCB and BOM | Design files in the agreed format | Design review, availability check |
| Controller firmware | Source code with build instructions | Tests on the prototype and in the equipment |
| Prototype units, assembled in-house | The agreed number of units | Bench tests, then tests in the equipment |
| Test report | Document | Results against the requirements, including fault conditions |
| Manufacturing package | Gerber or ODB++, assembly drawings, BOM | Review against the manufacturer’s requirements |
How the project runs
- You confirm that you own the equipment or are authorised to maintain it.
- The existing control unit and its role in the equipment are analysed.
- Requirements, permitted changes and acceptance criteria are agreed in writing.
- Circuits, PCB and firmware are developed.
- The bare PCBs are fabricated by a manufacturing partner; the prototypes are assembled and brought up in-house.
- The prototypes are verified on the bench and in the equipment.
- Design files, firmware, test report and manufacturing package are handed over.
See how we work.
What to send us
- A description of the equipment and the control unit.
- Photos of the unit and its place in the equipment; samples if possible.
- Available documentation: schematics, signal lists, protocol descriptions.
- What has failed or what needs to change.
Common questions
Do you program PLCs or build control cabinets?
No. We work on the electronics and firmware of control units: controller boards, interfaces and their firmware.
Can the new controller keep the original connectors?
Yes, when this is required. Form, fit and function compatibility is described on compatible replacement boards.
What if the controller firmware is not available?
Its behaviour is established from the existing unit and documentation, and new firmware is implemented, see firmware recovery and migration.
Can monitoring be added at the same time?
Yes. See industrial equipment telemetry.
Related services
Discuss the control electronics
Describe the equipment, the controller and what needs to change.
Discuss the control electronics
Confidential task? We sign an NDA before you share technical files.