Skip to main content

330-538-2268

Control System Design & Engineering

Designing control systems that perform reliably and stand up to real-world production demands.

A Structured Engineering Process, Built for Complex Systems

installation-supervision

Every control system project follows a consistent, phased approach that reduces risk, improves outcomes, and keeps projects aligned from concept through startup.

Phases of a Control System Project:

Pre-Engineering and Proposal

Electrical Engineering

Mechanical Engineering

Control System Manufacturing

Software Engineering (Level I and Level II)

Hardware Installation and Installation Support

Control System Testing

On-Site Commissioning

Post-Commissioning Support


This structured process allows PMC to manage complexity, maintain accountability, and deliver systems that perform as intended from day one.

Phase 1

Pre-Engineering and Proposal

The engineering process begins well before hardware is built or software is written. During the proposal phase, PMC conducts a comprehensive review of the machine, system, and operating requirements to ensure the project is properly defined from the start.

For existing equipment

Our engineers perform on-site evaluations to develop a deep understanding of current operation, limitations, and opportunities for improvement. 

For new equipment

We work directly with OEMs and equipment suppliers to understand mechanical movements, functional requirements, and sensing strategies. 

From this information, PMC develops a detailed proposal and quotation designed to support reliable budgeting. This includes accounting for not only the control system itself, but also adjacent hardware, software, and services that impact production performance—reducing surprises later in the project lifecycle.

Phase 2

Electrical Engineering

During the electrical engineering phase, PMC develops the technical foundation of the control system.

Selecting the correct hardware is critical to system performance, reliability, and serviceability. PMC engineers evaluate equipment options based on application requirements, operating conditions, and long-term support considerations.

This includes:

Electrical schematics

Control panel and layout drawings

Bills of material

Hardware research and selection

Phase 3

Mechanical Engineering

PMC provides mechanical engineering support to ensure control systems integrate cleanly with physical equipment and facility constraints.

When off-the-shelf solutions do not fit existing control rooms or shop floor spaces, PMC designs custom solutions that align with both operational needs and physical environments.

Typical mechanical engineering work includes:

Designing mounts for motors, encoders, and instrumentation

Supporting smooth and efficient installation processes

Designing custom consoles, cabinets, and enclosures

Phase 4

Control System Manufacturing

PMC operates an in-house panel shop to manufacture control system consoles, cabinets, and enclosures.

By keeping manufacturing in-house, PMC maintains:

Quality control

Shortens feedback loops between engineering and assembly

Ensures control systems are built exactly as designed

Phase 5

Software Engineering
(Level I and Level II)

The software engineering phase includes development of all necessary Level I and Level II control software, tailored to the application and operating environment.

Capabilities Include:

PLC Control Code

HMI and Operator Screens — Ignition, Wonderware, Rockwell FactoryTalk, Custom HMIs

Recipe and parameter management systems

Process Data Acquisition Systems — Ignition Historian, Wonderware Historian, Rockwell FactoryTalk Historian, Custom Data Acquisition Systems

Database Development and Integration — SQL Server, Oracle, PostgreSQL, Excel

Reporting

Phase 6

Hardware Installation and Installation Support

PMC provides both installation services and installation support to help ensure control systems are installed correctly and perform as designed.

This Includes:

On-site installation by PMC when required

Installation support for internal teams and electrical contractors

Technical guidance throughout the installation process

Ongoing engineering involvement to ensure the system aligns with the original design intent

Phase 7

Control System Testing

Before deployment, PMC fully tests control systems at our facility to support a smooth and efficient commissioning process.

Testing activities include:

Development of machine simulators to test systems without physical equipment

Factory Acceptance Testing (FAT)

Customer reviews and validation at the PMC facility


This approach allows issues to be identified and resolved early—reducing risk, downtime, and on-site commissioning time.

Phase 8

On-Site Commissioning

PMC deploys experienced engineers to the customer site to commission the control system and bring it into full operation.

Commissioning activities include:

Installation supervision

I/O checkout

Subsystem testing (motors, hydraulics, vacuum systems, cooling systems, manipulators, die slides, and more)

Cold commissioning through dry system cycling

Hot commissioning with product

System performance testing based on customer priorities


Performance testing may include running high-value products, operating under heavy loads, validating difficult production conditions, or conducting furnace surveys with tight temperature tolerances.

Phase 9

Post-Commissioning Support

PMC provides long-term on-site and remote support to keep control systems operating reliably throughout their service life.

Support services include:

Troubleshooting and diagnostics

Spare equipment support

Calibration services


PMC stands behind its control systems for as long as they remain in operation—supporting reliability, uptime, and long-term value.

A Partner Through Every Phase

From installation to long-term support, PMC Systems remains actively involved, ensuring your systems perform as intended and continue delivering value over time.

Request a Quote
Contact Us