Powering precision: electrical and pneumatic infrastructure design

For a global leader in life sciences and high-tech equipment, PDM delivered the detailed design of the electrical and pneumatic infrastructure for a new, complex machine. Acting as an extension of the customer’s engineering team, we ensured the timely, high-quality delivery of each work package. On budget and in full compliance with international standards.

challenges

The customer had already defined the machine concept and took ownership of the mechanical design. PDM was tasked with designing the electrical and pneumatic infrastructure.

This required seamless collaboration with the customer’s engineers while working within strict constraints:

Volume limitations: The machine, about the size of eight washing machines, offered very limited interior space. Cable routing had to be optimized to fit.

Electromagnetic compatibility (EMC): Certain components, such as position encoders, required shielding. This demanded smart cable choices balancing size, flexibility, and EMC performance.

Certification requirements: To access the US market, the design had to comply with Underwriters Laboratories (UL). All cabling, including motor connections, needed to meet UL listing or recognition standards.

pDM's Approach

To deliver on time and with precision, PDM deployed a dedicated “satellite team” of three design engineers who worked in close consultation with the customer:

Detailed infrastructure design: Using specified components such as power supplies, connectors, sensors, actuators, amplifiers, and compressed air valves, we mapped out the full electrical and pneumatic system.

Collaborative engineering: By aligning regularly on planning, status, and reviews, we maintained tight coordination and avoided rework. Cable chains for moving parts were designed in collaboration with the customer’s mechanical engineers.

Smart EMC solutions: Where standard cabling was too bulky for chains, we specified alternative thinner cables with sufficient EMC shielding.

Compliance and quality: UL requirements were integrated from the start, ensuring the machine’s suitability for the US market.

Results & ImpACT

The project successfully delivered all technical product documentation for the electrical and pneumatic infrastructure, including Eplan files and supporting documents.

Outcomes include:

A fully compliant design, ready for global deployment

Optimized use of limited machine space without compromising safety or performance

Enhanced engineering collaboration that minimized rework and accelerated delivery

Knowledge expansion within PDM, particularly in applying Eplan to pneumatic systems

Conclusion

By integrating seamlessly with the customer’s team, PDM enabled the delivery of a robust, compliant infrastructure design for a complex new machine. The project not only met deadlines and budgets but also strengthened PDM’s expertise in cross-disciplinary system design.

Curious how PDM can help you integrate electrical and pneumatic systems into your machines? Get in touch to explore how our teams can accelerate your development process.

Or are you excited to engineer infrastructure for complex machines? As an Engineer at PDM, you’ll work at the intersection of mechanics, electronics, and pneumatics – helping clients push boundaries and bring new machines to life. Join us and let’s design the future together!

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