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Controls Engineering

Controls Engineering

Controls Engineering

Controls Engineering

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From Concept to Controls, Delivering Exceptional Automotive Electrical Design

Sphinx Worldbiz is one of the largest ePLAN design service provider for all industries globally, offering full-spectrum controls engineering solutions that power-up automotive electrical designs with market-leading technology and software that boosts efficiency in automation in automotive manufacturing.

Certifications
Certifications
Certifications
Certifications
Certifications
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Controls Engineering Services for Successful BIW Designs

We are a world-renowned engineering and consulting services provider, specialising in advanced electrical design solutions for the automotive industry. Our expertise encompasses electrical BIW designs for robots, grippers, welding systems, conveyors, fixtures, automated guided vehicles (AGVs), end-of-arm tooling (EOAT), control panels, and complete production lines. We meticulously engineer these using ePLAN, AutoCAD, and AutoCAD Electrical.

With our expertise in controls engineering, we utilise CAE software to optimise designs for panel building, machine manufacturing, and plant automation that ensures maximum productivity and compliance with global standards.

Your Trusted Partner in Controls Engineering

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13,000+ Hrs Experience in Design

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Available in 19 Languages

Design Solutions and Support in 50+ Countries

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20+ Engineers Serving Globally

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Adhering to IEC 61439 & UL 508A International Standards

Some of Our 70+ Committed Customers

We are a global leader in 3D control panel design, streamlining the manufacturing process and reducing production time by 20%.

Our Product Offerings

Our Product Offerings
  • gearePLAN Electric P8
  • gearePLAN Pro Panel
  • gearePLAN Fluid
  • gearAutoCAD Electrical
  • gearE3 Zuken
  • gearDatabase and Micros Creation for all Electrical Software

Our Services

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Single Line Diagrams

Our electrical systems built on our single line diagrams ensure efficiency in control engineering and compliance with industry standards.

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Electrical Control Panel as Per All Standards

Our electrical control panels are designed for seamless automation and meet global safety and operational standards.

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General Arrangement Drawings

Our general arrangement drawings ensure precise placement for efficient automation by optimising space and functionality.

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Electrical Bill of Material Creation (BOM)

We provide a comprehensive BOM for precise procurement and smooth implementation in electrical engineering design services.

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Electrical Schematics

We create precise electrical schematics for control panels and systems, ensuring smooth automation controls design and efficient troubleshooting.

  • P & I diagram
  • Cable Layout & Cable Schedule
  • Pneumatic and Hydraulics Drawing
  • 3D Cabinet Design
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Panel Wiring Drawings

We provide panel wiring drawings with clear and detailed connections that allows flawless execution.

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Internal & Outer General Assembly of Electrical Cabinets

Our internal & outer general assembly drawings ensure efficiency with an optimised electrical cabinet assembly.

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3D Layouts of Control Panel

Enhance accuracy, refined control systems, and streamlined automation setups with 3D control panel layouts.

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Internal Layout of Panel

We deliver operational excellence in our internal panel layouts with optimal space utilisation and streamlined controls.

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Door Layout

Our door layouts are designed with compliance, safety measures and ease of use for enhanced panel accessibility.

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Inter Panel Cable Schedule & Cable Schedule Report

Our inter panel cable schedules & reports ensure reduced errors and improved efficiency.

OUR EXPERTISE

We create basic component data, engineering data & high-quality 2D & 3D data for various manufacturers. Our team has expertise in the following

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Single Line Diagram
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Power Diagram
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Control Diagram
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GA Diagram of panels
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LV and MV Control Panels
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All kinds of electrical boards

Highlights of Our Work

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ePLAN Example With Terminal
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ePLAN Example
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One of the Panels We Designed
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Panel With Internal
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ePLAN Pro Panel With 3D
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BIW Example
Finding Your Best-Fit Partners in Controls Solutions With The Following?
  • gearTrained Electrical Design Engineers with Years of Experience
  • gearAccurate & On Time Project Delivery ALWAYS
  • gearAccess To Talented Community Globally
  • gearTransparent Communication with Team

Sectors Where We Shine

Automotive
  • gearBody-in-White (BIW)rims
  • gearPaint Shop
  • gearConveyors
  • gearMaterial Handling
  • gearWelding Shop
Machine Builders
  • gearSpecial Purpose Machines (SPM)
  • gear CNC
  • gearCrane
  • gearFront and Rear Fender
  • gearPlastic Body Parts
  • gearTail Panel
  • gearLuggage Box
  • gearSide Panel
Control Panel Manufactures
  • gearMCC
  • gearPCC
  • gearLT Panels
  • gearPLC Panels
  • gearDistribution Boards
  • gearVFD Panels
  • gearSynchronisation Panels

Our Technical Expertise and Capabilities

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Partnership and Business Model

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Offshore

Our offshore teams deliver high-quality solutions with minimal onsite dependency and maintain high productivity.

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Onshore

We also offer onsite deputation of our experts for projects requiring close collaboration. Our engineers can work directly at client locations to ensure real-time coordination, faster issue resolution, and smooth project execution.

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Hybrid

We also offer a combination of the best of both models by developing dedicated Offshore Development Centres (ODCs) depending on customer needs to enhance flexible, scalable, and efficient solutions.

Our Testimonials

Let’s hear what some of our clients have to say about us. 

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Customisation Is the Key in All Our Solutions.

FAQ

Controls engineering services can help your company in several key areas:

• Increased Efficiency: Automation and optimised control systems streamline operations, reducing energy consumption and downtime.
• Improved Reliability: Robust control systems ensure your equipment operates consistently and safely, minimising errors and breakdowns.
• Cost Reduction: By automating processes and improving system performance, you can reduce labour costs and material waste.
• Scalability: Controls engineering helps design systems that can easily be scaled as your business grows or as production needs evolve.

Controls engineering is vital across various industries, including:

• Manufacturing: Automating production lines, controlling robotic systems, and integrating machinery.
• Oil & Gas: Monitoring and controlling extraction processes, refineries, and pipeline systems.
• Energy & Utilities: Managing power generation, distribution, and renewable energy systems.
• Automotive: Optimising manufacturing processes for high-quality, efficient vehicle production.
• Pharmaceuticals & Food Processing: Ensuring precision in critical production steps, like mixing, temperature control, and packaging.
• Building Automation: Managing HVAC, lighting, and security systems for efficiency and comfort.

Our process involves several phases:

1. Initial Consultation: We work closely with your team to understand the project requirements, existing systems, and desired outcomes.
2. System Design & Specification: We design control systems, selecting appropriate hardware, software, and components based on your needs.
3. Programming & Integration: We write software code (e.g., PLC programming, SCADA integration) and ensure smooth integration with existing equipment.
4. Testing & Commissioning: Once the system is installed, we conduct thorough testing and calibration to ensure proper operation.
5. Ongoing Support & Optimisation: After deployment, we provide continuous support, monitoring, and optimisation to improve performance over time.

We design and implement a range of control systems, including:

• PLC (Programmable Logic Controller) Systems: For automation and control of machinery, production lines, and processes.
• SCADA (Supervisory Control and Data Acquisition) Systems: For remote monitoring and control of processes across different facilities.
• DCS (Distributed Control Systems): For complex, continuous processes like power generation or chemical manufacturing.
• Motion Control Systems: For controlling the precise movement of robotic arms, conveyors, or automated vehicles.
• HMI (Human-Machine Interface) Design: To provide operators with intuitive control panels and dashboards for monitoring systems.
• Industrial IoT (Internet of Things) Solutions: For integrating sensors and devices into the control system to enable real-time data collection and analysis.

We prioritise reliability by:

• Redundancy: Designing systems with backup components to ensure continuous operation in case of failure.
• Testing & Quality Assurance: Thorough testing during every stage of development to identify and resolve issues before installation.
• Real-time Monitoring: Implementing monitoring tools to detect system performance issues early and allow for prompt corrective actions.
• Predictive Maintenance: Using data analytics to predict and prevent potential failures before they occur, ensuring systems remain operational.

PLC programming is essential in controlling automated processes. PLCs act as the brain of control systems, executing instructions based on real-time inputs from sensors and sending outputs to control machinery and equipment. We write custom PLC programs that ensure your systems function optimally and safely while being adaptable to changes in processes.

The timeline for implementing a control system varies based on the project’s complexity. Simple systems can take a few weeks, while more complex, large-scale systems can take several months. We work with you to define project milestones, ensure timely progress, and keep you updated throughout the process.

We provide comprehensive post-deployment support, including:

• System Monitoring & Maintenance: Regular checks to ensure system reliability and optimal performance.
• Troubleshooting & Optimisation: Addressing any issues that arise and fine-tuning the system to improve efficiency.
• Training: Providing training for your team to ensure they can operate and troubleshoot the system effectively.
• Upgrades & Expansions: Assisting with software updates, hardware upgrades, or system expansions as your business needs evolve.

We design control systems with energy efficiency in mind by:

• Optimising Processes: Streamlining operations to use less energy without sacrificing output.
• Energy Monitoring: Integrating energy monitoring capabilities to identify areas of excess consumption.
• Smart Scheduling: Scheduling high-energy tasks during off-peak times or automating systems to minimise energy use during idle periods.
• Feedback Loops: Implementing real-time feedback to adjust operations for maximum efficiency.

The cost of controls engineering services depends on several factors, such as the complexity of the project, the size of the system, and the type of control system required. We offer customised quotes based on your specific needs and budget. Our goal is to provide you with a high return on investment by designing systems that enhance productivity and reduce long-term costs.

Yes, we specialise in retrofitting and upgrading legacy control systems. We can help modernise your outdated systems, integrating newer technologies for better performance, reliability, and ease of operation. Whether it’s upgrading PLCs, incorporating IoT devices, or enhancing HMI interfaces, we ensure that your system stays current and efficient.

To get started, simply reach out to us via our website or contact us directly. We’ll arrange a consultation to discuss your specific needs, assess your current systems, and provide a tailored proposal. From there, we’ll work together to design and implement a control system that meets your goals.