HMWS Case Study: Plug and Play Electrical System Design
August 24, 2023

Project overview

In the demanding world of drilling operations, reliability, serviceability, and efficiency are key factors that drive success. HMWS recently undertook a groundbreaking project involving a complete redesign of the electrical architecture and associated harness and cable assemblies for a fleet of Epiroc Pit Viper 271 Rotary Blasthole Drills.The objective was to develop a plug and play solution that would minimise downtime, enhance serviceability, and improve reliability in remote operating environments. In this case study, we will explore how we were able to deliver an outstanding outcome for our partner.

The Brief

Action Drill and Blast, a company operating a large fleet of drill rigs in remote locations, sought a solution to mitigate the risk of downtime and troubleshooting. They turned to HMWS to develop a plug and play wiring system that would meet their specific requirements. The brief emphasised the need for a seamless integration of components and a dashboard layout that accommodates the plug and play system.


HMWS approached the project with meticulous attention to detail and a comprehensive understanding of the challenges faced in the drilling industry. The plug and play design included several key deliverables:

Enclosures: HMWS designed protective electrical enclosures, eliminating cable splices and serving as breakout hubs for controls and sensor circuits. These enclosures offer added protection in harsh environments and include LED internal lighting and diagnostic connectors for maintenance crews.

Overmolded Cables: The plug and play design features overmolded cables with strain relief, integrated LED lighting for fault-finding, and enhanced protection against water ingress and oxidation. These cables use a Hi-Flex cable with tinned copper braided protection and a flexible polyurethane thermoplastic outer sheath for improved integrity and resistance.

Limit Switches and Dashboard: HMWS redesigned and manufactured limit switches and the operator’s dashboard, enabling seamless plug and play integration. Weld-in bulkheads on cabin walls maintain system integrity and optimise serviceability in remote areas.

Trunk Cable and Bulk Heads: Harness joins were eliminated with a simple trunk harness connecting all relevant electrical enclosures. Bulkhead connection panels were implemented to improve electrical harness life and reliability, with connector labelling for fast identification and future expansion.

The outcome

The plug and play solution implemented by HMWS yielded significant benefits for Action Drill and Blast. The seamless integration of the electrical system and the enhanced serviceability resulted in reduced downtime and improved troubleshooting capabilities. The design and components provided by HMWS allowed the client’s team to focus on installation, leading to a successful outcome.


David Comrie, Workshop Manager at Action Drill & Blast, expressed his satisfaction with the project, stating, “We’d highly recommend the HMWS team as they were awesome in their delivery of the design and components for installation. The one company approach allowed my team to focus on the installation and resulted in a great outcome.”