Unstable synchronisation
Speed, capstans, dancers and winders have to react together, without constant corrections from the operator.
Industrial sector
Automation for cable and fiber optics
Panels, machine side, PLC/HMI/SCADA software and start-up for lines where tension, synchronisation and reel history must stay under control even on 24/7 cycles.
- Controlled tension
- Extrusion
- Buffering
- Winding
- Reel history
24/7
line continuity and readable restarts
PLC / HMI / SCADA
reel data, tension and diagnostics in a single flow
What we solve
The technical questions that matter before the quote.
When a cable line slows down, the problem is rarely a single component: you need consistent signals, clear logic and data that is useful to the people running the line.
Scrap that is hard to read
Alarms, trends and line states help understand whether scrap comes from tension, temperature, recipe or the start-up phase.
Scattered reel data
Batch, parameters, progress and anomalies must be reconstructable without parallel spreadsheets or manual steps.
Risky start-up
FAT, tested sequences and documentation reduce surprises when the plant enters production.
Related services
The D&D services for a cable-production plant.
From the electrical schematic to the software, from the panel to start-up: every service has a clear scope and stays coordinated with the others.
Schematics, BOMs and panel architectures for extrusion, drawing and winding lines.
Line synchronisation, operator interfaces, diagnostics and traceable reel data.
Tidy wiring, traceable components and electrical tests before delivery.
Signal tests, proven sequences and commissioning of the line in production.
From field to data
One single flow between machine, panel, software and testing.
D&D connects sensors, panel, drives, PLC and supervision into a readable chain. The goal is to know what is happening on the line before it becomes downtime or scrap.
Automation designed for those who have to produce, verify and maintain.
The line isn't seen as a sum of machines, but as one continuous system: field, panel, software and operator must speak the same language.
Field
Sensors, actuators and real signals
Survey of critical signals, machine conditions, field networks and operating constraints.
Panel
Power, machine side and safety
Electrical schematic, I/O, drives and components organised for testing and maintenance.
PLC / HMI / SCADA
Logic, diagnostics and data
Sequences, recipes, alarms, trends and operator pages built around the process.
Testing
FAT, start-up and restart
Functional tests, checks with the customer and field support through to production.
Typical applications
Where the intervention has to create control, not complexity.
Each sector page goes into the detail of the areas where D&D can bring electrical, software, testing and operational support.
Extrusion and coating
Control of temperatures, speed, enables and line recipes.
Buffering and accumulation
Tension management, synchronisation and transitions between modules.
Winding and reels
Logic for diameters, layering, reel change and traceability.
Testing and measurement
Integration of signals, instruments and quality data.
Existing-line revamping
PLC/HMI migration and panel upgrade with planned downtime.
Production supervision
Reel history, recipes, alarms, trends and operational reports.
D&D method
First understand the process, then write the software.
On cable lines you don't need a generic solution. You need a technical reading of constraints, signals, downtime, operators and real goals.
Signal and speed analysis
FAT on critical sequences
Start-up with real production
Analysis
Technical constraints and production goal
We collect documentation, plant status, recurring problems and the expected result.
Design
Consistent electrical and software
Panel, PLC, HMI and supervision are designed as one operating system.
Testing
Tests before the field
Critical functions are tested to reduce the risk at start-up.
Start-up
Support through to production
The final step is making the solution usable by operators and maintenance.
Related experience
Projects and resources to start from.
Concrete references to understand how D&D translates the sector into automation, panel, software and testing.
Flagship project
Open the case study
Ulisse vessel marine cable-laying plant
Automation and control for an operating system aboard the Prysmian Group vessel.
Coming soon
Available soonNew case study
A new real plant from this sector will be online soon, with context and results.
Operational questions
Quick answers before the first technical discussion.
Can you work on a cable line already in production?
Yes. First we gather the schematic, installed PLC/HMI, symptoms and downtime constraints; then we define an intervention compatible with production, testing and restart.
Do you handle tension, capstans and winding in the same project?
Yes. The value lies precisely in coordinating field signals, drives, PLC logic and HMI, avoiding disconnected adjustments between modules.
Do you need to rebuild the whole panel to improve the line?
Not always. Early on we separate what should be kept, what should be migrated and what is worth rebuilding for reliability, safety or maintenance.
What information is needed for a first discussion?
Useful items are the line layout, PLC/HMI brand, electrical schematics, a description of downtime or scrap and the expected goal: new line, revamping, diagnostics or supervision.
Technical contact
Tell us about your cable-production plant.
You don't need a complete specification. The sector, machine or line, goal and main constraints are enough: your request reaches the D&D technical team already in context.
- An initial technical read of the request.
- Request sent with the sector and source page.
- Reply within 1–2 business days when the data is sufficient.