Advancing Solar Tech with OT & Automation
Industry
Renewable energy sources
Scope
OT
Timeframe
12 months
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1
year
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2
IT/OT Engineers
01
CLIENT
An independent research and development center specializing in innovative photovoltaic technologies. It is the first company in Poland to launch a production facility for next-generation solar modules, characterized by flexibility, lightweight design, and high efficiency across diverse lighting conditions.
02
BUSINESS NEEDS
Our client required comprehensive support in the areas of Operational Technology (OT), automation, and software solutions to successfully commission the production line used for production of photovoltaic modules.
The first challenge was to thoroughly understand the existing technology. We began by conducting a full inventory of all equipment and performed reverse engineering based on the original C++ source code. The machine was delivered to the customer in parts without a control unit, so our task was to select the control PC (IPC) and appropriately configure the necessary hardware and software, and ensure the production line was operational, safe, and ready for manufacturing.
To guarantee reliability, we ran rigorous hardware and software diagnostics, tested all system components including electrical and network connections, and delivered thorough commissioning documentation, giving the client full confidence in system integrity.
03
CHALLENGE
To help our client achieve its goals, we overcome the following challenges:
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Reconstruction and reconfiguration of a C++-based control system
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Configuration and diagnostics of Profibus communication networks
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Testing and verification of all I/O modules
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Setup and validation of servo drives, pumps, and heating units
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Preparation of extensive commissioning documentation to validate system readines
04
SOLUTION
We delivered comprehensive commissioning support for the production line in accordance with the customer's guidelines, ensuring all hardware and software components were properly integrated and operational our work included:
- Technology Analysis Thoroughly understanding the existing technology of the production line that had been inactive for several years.
- Equipment Inventory and Reverse Engineering Conducting a detailed inventory of all hardware components and performing reverse engineering based on the original source code to reconstruct system logic.
- Devices and fieldbus configuration Executing hardware configuration including testing and diagnostics to ensure operational integrity
- Control Unit Configuration Preparing a control unit compatible with the software and hardware. Integrating and configuring the control unit within the existing infrastructure.
- Comprehensive Testing Conducting extensive tests of all production line components to validate functionality, interoperability, and readiness for production restart.
- Documentation Preparation Developing detailed and comprehensive commissioning documentation covering all aspects of the production line commissioning.
This project was a great example of how deep technical expertise combined with structured project execution can bring even the most fragmented systems back to life. We rebuilt the production line piece by piece—literally and logically—ensuring everything worked seamlessly together. It’s rewarding to know our work directly supports the growth of renewable energy innovation in Poland.
Krystian Maskulanis
Industrial Systems Engineering Lead
Technology used
05
OUTCOME
The comprehensive commissioning and modernization of the photovoltaic production line resulted in a highly efficient and reliable system tailored to the client’s specific needs. Our solution not only restored the line’s full operational capability but also enhanced its reliability and safety standards. The following key outcomes highlight the value delivered through our meticulous approach and technical expertise. This outcome supports the client’s goal of advancing photovoltaic technology manufacturing with a modernized, efficient, and safe production environment.
We provided effective and reliable commissioning support that:
- Fully met the client’s operational and technological requirements.
- The system seamlessly integrates advanced software solutions with physical components, ensuring smooth and efficient operation of the photovoltaic module manufacturing process
- Throughout the project, we maintained a strong focus on operational safety, ensuring the system complies with stringent industry standards.
- The comprehensive testing, diagnostics, and detailed commissioning documentation provided the customer with full confidence in the production line’s readiness and long-term performance.
06
IMPLEMENTED SOLUTION
- Conducted an in-depth analysis of a large and complex C++ based control application
- Performed extensive debugging of the existing software to identify and resolve errors and inconsistencies caused by the prolonged downtime
- Modified and updated the source code to adapt the system to current operational and hardware requirements.
- Configuration and testing of input/output modules, pumps, servodrives, heating modules
- Connecting, diagnosing and configuring of PROFIBUS communication networks
- Preparation of nearly 700 pages of commissioning documentation covering all devices in the production line.
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1
year
-
2
IT/OT Engineers