Our ContributionsOur client planned their controls and information systems improvements over a two year period. Their goals were to have both supportable equipment and current components. The first phase had Primary Systems Inc. oversee the upgrading of the client’s Allen-Bradley PLC/Motion Controllers as well as their HMIs and vision systems. The second phase had PSI upgrade the client’s servos and I/O. The client’s seventeen servos were no longer supported by the
manufacturer. Production yields were being negatively impacted by breakdowns and downtime. Tom Palovchak, Senior Systems Engineer for Primary Systems Inc., assessed the production line and recommended replacing all 17 servo controllers and motors with 13 new Allen-Bradley Kinetix-6500 Servo Systems and new Allen-Bradley Control Logix 1756-L72 PLCs. Allen-Bradley Flex I/O had previously connected to the client’s proprietary network. PSI upgraded this to Ethernet using adaptor modules which allowed for most of the signal wiring from the I/O to the field devices to “stay put”. The new servos and PLCs also communicated over Ethernet, enabling easier setup and troubleshooting. Primary Systems Inc. recommended the Allen-Bradley PLC/Motion Control solutions for 3 reasons: - Ease of communications to the existing Allen-Bradley Flex I/O;
- Ease of communications and integration between the servos, motion controllers and HMIs; and
- Easy availability of spare parts and flexible servicing options for the foreseeable future.
Finally, Primary Systems Inc. prioritized the processing code. By taking advantage of the increased speed of the new processors, all
logic and motion control can now be handled by a single CPU instead of the previous two units.
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