【2025 Technical Essentials】Knowledge Needed for Custom Design

1. Understand requirements and master project management skills. The biggest characteristic of custom design is that each project is unique. This means you need to have a very clear understanding of customer needs and production processes, as well as a precise grasp of the project background. This requires designers to be not just “technical craftsmen,” but also to possess certain project management skills. How to communicate effectively with clients, how to break down requirements, and how to develop design solutions based on the clients’ ultimate goals – all of these need to be clarified at the beginning of a project.

How to do it: Conduct a detailed requirements analysis: Obtain a comprehensive set of requirements documents through on-site inspections, technical discussions, experimental tests, etc., to ensure that nothing is overlooked. Communication and coordination skills: During the design phase, the ability to communicate effectively with various parties such as equipment suppliers, production teams, and commissioning staff, in order to coordinate resources from all relevant areas. Schedule and budget management: Reasonably arrange the schedule, resources, and budget, and address any unexpected issues that arise during the design process in a timely manner.

2. Fundamentals of mechanical design: These are the core of custom design. Mechanical design forms the basis for custom automation. Before proceeding with any design, you must have a solid foundation in mechanical design. This includes a deep understanding of mechanical principles, as well as proficient use of common transmission systems (such as gears, couplings, belts, etc.) and motion types (such as linear, rotational, oscillating, etc.).

How to do it: Master standard part selection: Use the standard part library proficiently to choose appropriate standard components in order to reduce costs and improve design efficiency. Mechanics and motion analysis: Structural and dynamic analysis is carried out using tools such as Finite Element Analysis (FEA) and motion simulation to ensure the feasibility and stability of the design. Design optimization: For complex assembly structures, it is necessary to understand assembly tolerances, transmission design, and kinematic analysis in order to minimize manufacturing difficulties.

3. Electrical and control systems: The key to automated design. In custom automation projects, electrical design and the design of control systems are often very important aspects. The stability and level of intelligence of the control system directly affect the operational efficiency of the entire device. Mastering the basic principles of automatic control and being able to design appropriate electrical control systems based on specific requirements has become an essential skill for modern custom design professionals.

How to do it: Basics of PLC programming: Master the fundamental principles and programming of PLC control systems, and be able to write and debug programs based on the actual requirements of the equipment. Selection and application of sensors and actuators: Understand the working principles and application scenarios of common sensors (such as position sensors, pressure sensors, temperature sensors, etc.) and actuators (such as electric motors, pneumatic cylinders, etc.). Fieldbuses and communication protocols: Understand fieldbuses such as Profibus, EtherCAT, Modbus, etc., and their use in custom designs to ensure interoperability between different devices. Safety control design: In accordance with industry standards, a safe control system is designed to ensure that no safety hazards arise during human-machine interaction and automation processes.

4. Process and manufacturing knowledge: No matter how perfect the design drawings may be, if the feasibility and practicality of manufacturing are not taken into account, the final outcome may be significantly compromised. The design of non-standard equipment requires close integration with the actual conditions of the production process and manufacturing techniques; it is necessary to select appropriate processing methods in order to reduce processing difficulties and improve production efficiency.

How to do it: Mastering common processing techniques: Understand common mechanical processing methods such as milling, turning, welding, casting, etc., and select the appropriate processing route based on the requirements of the components. Assembly process analysis: Considering the difficulty of assembling the equipment, the fit between parts and the assembly procedure are designed appropriately. Process optimization and cost control: Optimize the design while ensuring functionality, reduce unnecessary complex processes, and lower manufacturing costs.

5. Debugging and after-sales service: The final step in the design process. The debugging and after-sales service of custom-made equipment is a aspect that is often overlooked, yet it is crucial for the smooth operation of the entire project. Designers need to possess basic skills in debugging and maintenance, enabling them to work with technicians on-site to resolve issues and ensure that the equipment is delivered on time to meet customer requirements.

How to do it: Mastering the debugging process: Understand the basic procedures for equipment debugging, and be able to develop detailed debugging plans based on the actual conditions of a project. Troubleshooting ability: Master the techniques for identifying and resolving common equipment failures, thereby improving the efficiency of handling issues on-site. Equipment training and technical support: Provide customers with detailed training on equipment usage and maintenance to ensure they can operate and maintain the equipment independently.