Case Study

Automation in Cabling.
From DXF drawing to automatically generated cable list

All references

Electrical Design. Automation and Planning Department

Automation in Cabling: Saving Time in Plant Planning

Extraction of equipment positions and all necessary cable lengths from DXF layouts. Created through pathfinding and automatic generation of optimal cabling.

Projekt
Automation in Cabling: Saving Time in Plant Planning

Kategorie
Electrical Design. Automation and Planning Department

Aufgaben im Projekt

  • Concept Development
  • Implementation
  • Rollout

Technologien
DXF, Python, Excel, ERP Integration

The Project

Before

The placement of cable trays, sensors, motors to distribution cabinets was done manually. Cable lengths were measured from the model and noted in lists. Large cable allowances and position changes led to rework and increased costs.

After

Handing over the CAD file to the cable tool enables fully automated connection of all sensors and actuators to distribution cabinets. Cable lengths are automatically determined and parts lists created, leading to time savings, cost reduction and quality improvement.

1/4

Initial Situation

The cabling of large industrial plants is a complex process, as thousands of components are managed in a model. After completion of the planning, a parts list of all required sensors, actuators and cables must be derived from this layout. The necessary cable path must be determined and recorded in a list for each one. In the end, there is a list of the number of all required cables with the correct lengths, properly labeled and prepared for the construction site. All these steps were determined by measuring the line lengths in the CAD model and the positions of the associated sub-distributors or control cabinets.

Overview: Cable trays, sensors and actuators in a plant
Excerpt from the plant: A group of symbols
Excerpt from the group: Some symbols
Example of a symbol
A symbol and its attributes

2/4

Concept & Design

Development of a tool that automatically determines cable lengths based on DXF-CAD drawings and documents them. The connection of sensors, actuators and sub-distributors is created via a graph. The derivation of all necessary further information into the existing ERP for easy ordering is the focus.

1. Decision Process

  • Analysis of manual steps
  • Creation of typical pilot layouts from existing projects
  • Evaluation of in-house development vs. commercial solutions

2. Concept

  • Requirements for layout, routing logic, and output formats
  • Interfaces to CAD, Excel, and ERP (article numbers)
  • Configurable rules for equipment detection
  • Technical framework: Python environment, layer structures, and DXF element attributes

3. Solution

The tool reads DXF files, calculates cable routes automatically, and delivers Excel lists and DXF files with the cable paths for direct use. All processes are automated without user input.

Step 1: DXF plan of cable tray routing
Step 2: Transfer to the program
Step 3: Generation of cables to sensors 1 to n
.. Cable to sensor 2
.. Cable to sensor 3
.. Cable to sensor 4
Further procedure shown representatively on cable 1
Step 4: Decomposition of a cable into sections
 
 
 
Step 5: Determination of the length
 
Step 6: Assignment to an orderable cable from the ERP
Step 7: Repetition for all included cables
Step 8: Creation of the cable file and Excel list with ERP data

3/4

Implementation

1. Development

  • Specification of software components for automated cabling (coordinate extraction, routing, result generation)
  • Development of routing logic and equipment detection including unit tests
  • Modular architecture with clear interfaces to Excel, CAD, and ERP
  • Iterative testing using pilot layouts

The cable evaluation is based on a DXF file created by the automation department to represent the layout. The challenge was reliably detecting components such as actuators, control cabinets, and sensors and identifying their logical connections via polyline paths. A robust parsing logic was developed using defined symbols and geometric relationships to interpret the cabling and automatically generate cable lists.

The tool-generated lists include not only source and destination points, but also ERP-relevant information like part numbers, connector types, and cable lengths. A direct ERP connection was prepared, but initially implemented via structured Excel formats. This allowed for manual verification and progressive automation.

For reliable operation, clear standards for layer names, symbols, and attributes had to be defined. A central symbol library and mandatory conventions ensured a unified data structure — essential for scalable use.

Cable evaluations, preparation lists, cutting lengths, and documentation overviews are all generated at the press of a button. Template-based layouts allow customer-specific formatting. An automated plausibility check detects issues like duplicate labels or open ends early on — without manual intervention. A comprehensive error report provides the possibility for manual correction within the layout.

Typical errors — such as unconnected lines, duplicate IDs, or incorrect layers — are automatically detected and logged in a dedicated error report. This prevents incomplete or inconsistent data from being used further. Errors are listed in a dedicated Excel worksheet for manual correction.

2. Rollout

  • Tool integration into the design process
  • Documentation and usage guidelines
  • Adaptation of CAD-DXF generation workflows
  • Incorporation of Excel outputs into planning and procurement processes

Clear documentation and process guidelines enabled fast adoption. Integration with existing Excel-based workflows ensured smooth acceptance across departments.

Drop the DXF file onto the program
DOS box of the program executing the pathfinding
Result files: .dxf and .xlsx
View into the .dxf file with the cables
 

4/4

Result

The time required from design to a ready-to-order assembly has been significantly reduced. Many error-prone, manual activities in the layout are eliminated – instead, automated workflows take over recurring tasks such as pathfinding, length calculation and parts list creation. The system is therefore not only a tool for evaluation, but a central element in the standardization of electrical engineering. It forms the basis for further digitalization steps in the entire product development process.

Michael Stangl

Interested?
I look forward to your inquiry!

Michael Stangl
Managing Director