reverse engineering project
PCB hardware reverse engineering projects
We have vast experience in the field of electronic hardware reverse engineering. If we haven’t made your exact product before then we’ve probably made something similar. Our reverse engineering laboratory is not only able to make your electronic circuit board replacement as a clone, copy or upgrade (assuming the PCB is unsupported by the OEM) we can also reproduce your hardware using our state of the art 3D printer.
See below for just some of the products we have reverse engineered, see the see our ENA’s 8 step Electronic Hardware PCB Clone, Copy + Upgrade Process to see how we did it.
8 Layers, Leght of traces 62922mm, Number of holes 2002, Vias 1064. Twin Central Processing Unit – two complete CPU systems on a single-slot VME BUS module. VME BUS interface, slave interface, controller extension connector.
This project was a reverse engineering project for an obsolete product. For this project we reverse engineered both the current transformer and the power transformer and sourced hard to find/obsolete parts.
This project was interesting for us as the customer asked us to take a military grade PCB and make it out of regular off the shelf parts. Included in this reverse engineering project was making our own custom potted modules and finding replacement ICs.
Part of the same project as Control Logic A we took the military grade PCB and made an industrial version. With our huge supply network we were able to source hard to find parts and clone the board ready for our customer.
A million dollar machine was down because the go button stopped working. We got a hold of the keypad, worked out the pinout and developed a replacement keypad. The customer installed the keypad and with one press they were back up and running.
We made this replacement keypad as the original keypad was worn and broken, the customer had no options left with nothing on the market. We took the original design, designed the files and manufactured a replacement which the customer was able to use right away.
The customer had a damaged HMI overlay. The replacements were unavailable so we made a replacement, this allowed the customer many more years of use on the HMI.
In this reverse engineering project we upgraded an original Allen Bradley Series 9 HMI’s keypad with a cloned + upgraded tactile switch equivalent. This retrofit allows future repair much needed in demanding environments.
This card was a 4 layer PCB communicating through a backplane to a controller running on VMEBus. Once we built the card we made a full function test rig.
This backplane even came in with burnt components, we reverse engineered the schematic from the PCB + cloned the board, upgrading parts for modern equivalents.
Our customer came to us asking if we could reverse engineer a board they were having trouble with. We not only cloned it but we built a test rig + helped with the commissioning.
This control card clone allowed the customer to drop in a replacement for their obsolete machine, saving them thousands on a new machine + giving them spares for the future.
After sourcing the hard-to-find components for this industrial control relay card we sent it to the customer. Needless to say it worked the first time.
This device was a brand new design for us. The device connected via RS232 to a VFD drive + by using our custom firmware they could control their drives.
Particular attention to detail was required on this project as the customer required over 30 units + they were for a nuclear power plant – they had to work the first time.
The customer came to us with an old, non-working controller + asked for a replacement. We designed + manufactured this unit from the ground up.
Not only can we reverse engineer PCBs with through hole components but we have facilities to populate + solder SMD’s (Surface Mount Device) too.
A large multi-national company came to us with this reverse engineering project. They needed their bandboard circuit made into a modern PCB. This is what we came up with.
This switched mode power supply needed to be an exact fit-form-function replica for the customer. We even custom made the switching transformer!
The customer gave us the original board + asked for some feature upgrades on the old board. We added power + function LED’s + connectors.
This PCB required extremely high precision resistors + components that were obsolete. We not only sourced them but supplied 50 units to our customer.
The DC-DC power supply on this card was completely unavailable. We sourced a replacement, upgraded the board + provided documentation.
Burny 1400 Llus Replacement Keypad
Original, Version 1, Version 2, Version 3
24 opto-isolated digital inputs for up to 60VDC
16 opto-isolated 24 VDC outputs.Smart transistor outputs
Customer Email “I have a need for reverse engineering of multiple circuit boards that we have for a machine type in which we have 24. There are probably at least 10 boards per machine. The boards are over 20 years old and have been repaired too many times. We have some electrical drawings that we can provide. Please let me know what you need in order to quote building these for us so that I can get all of the pertinent information together for you.”
(Wind turbine) 3D Design and Fabrication
RTD 200 input output 4-20 mA Tolerance 0.1%
RS232 communication, two 8K by 8 EPROMS, WD relay, LEDs, 15 pin DSUB
Replacement Board for ML4006L3315G001
Replacement for obsoleted Snubber Board
PELI-0134-05
legacy product remanufacturing
reverse engineering project: value added services
Reverse engineering includes more than just cloning and upgrading. The process of creating or recreating a full assembly can also include manufacturing covers, casings, or overlays in addition to incorporating batteries into the assembly.
3D printing
Metal is not always the most conducive medium for all builds. Some things need to be light and ergonomic, yet durable. Both engineering projects and repairs can involve replacing plastic casings but for a custom design and when two dimensions just aren’t enough, 3D printing is the best option. Our 3D printer has a large print volume enabling prints up to 400mm x 400mm x 700mm. Get in touch with your project requirements for a quote.
vinyl + lexan overlays
Much like how a common HMI can have its overlay replaced as part of its repair, so too can a custom overlay be manufactured as part of an engineering project.
battery spot welding
Some assembly is required, but batteries are always included. Using a battery spot welder we can make our own battery packs and battery assemblies for any engineering + repair project. We can produce any battery that you need for backup or your custom reverse engineering project.