Control System Upgrade with 3 Weeks of Machine Downtime

Project Overview

AG Controls completed a control system upgrade for an automotive manufacturer based in Yorkshire (UK).

The work was prepared in advance and executed during a planned shutdown.

Total machine downtime was limited to 3 weeks, after which the line returned to production.

The Starting Point

Two main issues were identified.

Obsolete servo system

• The existing servo drives were no longer available
• Spare parts were sourced from secondary markets

Legacy PLC software

• Based on STEP7 (classic) with STL code
• Difficult to read and modify
• Limited structure for sequence control
• Troubleshooting required specific experience

 

Scope of Work

• Removal of the existing control panel and wiring
• Installation of 9 servo drives
• Installation of 5 HMI stations
• New control cabinet build
• Full electrical design
• New PLC software
• Mechanical adapters for servo integration

Control System

The system was rebuilt using:

• Siemens S7-1500 PLC
• ET200SP I/O
• Profinet network
• Integration with existing devices over Profibus

Operator panels:

• Siemens Unified HMIs (MTP series)

Software

The new software was developed in:

• TIA Portal
• Graph for sequence control

This provides:

• Clear sequence structure
• Easier diagnostics
• Simpler future changes

Mechanical Constraints

The existing machine layout was kept.

New servo drives were integrated using custom adapter plates – designed at AG Controls , without modifying the main structure.

Execution

Most of the work was completed before the shutdown.

• Electrical design
• Software development
• Documentation including 116 pages of schematics and layouts

On-site work included:

• Strip-out
• Installation
• Commissioning

Result

• 3 weeks downtime
• Machine returned directly to production
• Obsolete components removed
• System easier to maintain

Feedback

“This was one of the best upgrade projects I have seen.”

Controls Engineer

Summary

The main goal was to remove risk caused by obsolete components and simplify maintenance.

The upgrade was completed within a defined shutdown window and without changes to the machine layout.

Need to upgrade existing equipment?

If you are dealing with:

• Obsolete drives or control hardware
• Limited spare parts availability
• Difficult-to-maintain legacy software

AG Controls can support both engineering preparation and on-site execution within a planned downtime window.