Details
Service Breakdown
Services (quick list)
- Custom industrial controller design and build
- Industrial controller repair, diagnostics, and reverse engineering
- Relay panel and control board design
- Custom circuit design and embedded system development
- Control system firmware and software
- Prototyping and small production runs
- Legacy controller replacement and redesign
- Supporting software, dashboards, and remote monitoring integrations
Industrial controllers & control systems (detailed)
Custom industrial controllers are built around the specific application — not adapted from a general-purpose PLC with features you don't need and gaps you have to work around.
Design scope
- Requirements capture and control system architecture
- I/O specification: digital inputs/outputs, analogue signals, relay channels
- Power supply design for the operating environment (24VDC, 12VDC, mains-derived)
- Industrial communication protocol implementation (Modbus RTU, Modbus TCP, RS-485, serial)
- Safety interlocks and fault detection logic
- Remote access, monitoring, and control interfaces (MQTT, REST, web dashboard)
Firmware & software
- Deterministic real-time firmware for reliable process control
- State machine design for safe sequencing and fault recovery
- Watchdog, power-fail, and recovery logic
- OTA (over-the-air) update support where required
- Web-based configuration and monitoring interfaces
- Integration with backend platforms, SCADA, and historian systems
Enclosure & installation
- Panel layout design and DIN rail configuration
- IP-rated enclosure selection, modification, or in-house fabrication
- Cable management, labelling, and installation documentation
- Commissioning support and field acceptance testing
Full-cycle custom electronics development (detailed)
Beyond isolated board work, we design and build complete embedded systems from concept through deployment.
Design & engineering
- Requirements analysis and system architecture
- Custom PCB design (schematic, layout, routing)
- Firmware development for microcontrollers and embedded systems
- Network protocol implementation (serial, Modbus, TCP/IP, etc.)
- Safety and regulatory compliance assessment
Manufacturing & fabrication
- PCB prototyping and small-batch production (sourcing, assembly, programming)
- 3D design and modelling for custom enclosures
- 3D printing and additive manufacturing for prototype enclosures
- CNC subtractive manufacturing and machining
- Mechanical assembly and integration
Testing & validation
- Functional testing and verification
- Environmental suitability (temperature, humidity, salt spray)
- Waterproofing and IP rating validation
- Vibration and shock resistance testing for harsh environments
- EMC / EMI compliance testing
- Field trials and reliability assessment
Example: Industrial controllers for harsh-environment deployments
Example engagement: networked industrial relay controllers for offshore aquaculture operations in demanding environments.
- Custom multi-channel relay PCBs with industrial-grade relays rated for the load
- IP67-rated enclosures designed, prototyped, and manufactured in-house
- Waterproofing and corrosion protection for salt-water spray and high humidity
- Modbus TCP and Ethernet connectivity for remote monitoring and control
- Cellular (4G) fallback for sites without fixed network infrastructure
- Power management for marine and off-grid power systems
- Environmental testing to validate performance in offshore conditions
- Deterministic firmware for reliable low-latency switching
- Web dashboard for operator visibility and remote control
This kind of engagement spans electronics design, firmware, enclosure engineering, networking, and software — delivered as a single scope with documented handover.
Controller repair, diagnostics & reverse engineering
Industrial controllers and control boards fail. When they do, the options are often: replace the whole unit at significant cost, wait weeks for a specialist, or find someone who can diagnose and fix it locally.
- Board-level diagnostics on industrial controllers, relay panels, and control electronics
- Component-level fault finding and repair
- Reverse engineering of undocumented or obsolete controllers
- Redesign and replacement where repair is not viable
- Firmware recovery and re-flashing where applicable
- Documentation of repaired or reverse-engineered designs for future reference
If you have a failed industrial controller and need it assessed, bring it in or contact us to discuss. Darwin-based — no need to freight it interstate.
Repairs and one-off work
- Diagnostics and troubleshooting of existing electronics
- Repair of damaged components, PCBs, and controllers
- Reverse engineering to understand and modify existing designs
- One-off repairs and bespoke modifications
A broken controller, damaged PCB, or small electronic device is worth discussing if it can be repaired safely and reasonably.
For infrastructure and business IT services see our IT page: iatrt.com/it.