A complete electronic retrofit
of a 10-elements packaging press.
Made with industrial ethernet network of Powerflex DC – L82 PLC – 5069 series IO racks – SCADA made with a new wonderware intouch R2020 application, the entire automation software was re-written in one single PLC that replaces the old three reliance-electric plc’s.
The new automation software was made with data structures and modern tasks with logic blocks / motion blocks / subroutines / functions, all the variables traslated into new formats.
The new SCADA application was built to maintain the exact function of the old one for ease of use.
Documentation is made with a new set of electical drawing to describe the update process, and for reference.
Here’s some image of the machine (BEFORE / AFTER ):
PLC :
The original automation where made with three Reliance Automax PLC’s , now replaced by a single Allen Bradley – Rockwell L82 – PLC. 
Main Motor drive:
Independent drives:
Input / Output racks:
the old SLC-500 racks was replaced by the newest L5069 series Allen-Bradley racks with industrial ethernet connection.
Ventilation:
Old GV3000 with one temporary repaired drive was replaced with PowerFlex-400 series inverters.
Unwinder / Rewinder:
New Powerflex dc – I/O and PLC removal both in unwinder and rewinder racks…
Panels:
Old custom made operator panels was replaced with modern Allen-Bradley panel-view.
SCADA:
the ~20 year old pc was replaced by an industrial fanless pc with ssd and windows10 64bit running the latest release of Wonderware InTouch 2020-R2, with the new application made to be close to the original for ease of use by the operator.
In short,
all the old hardware, obsolete and no longer available, has been completely replaced by the most modern devices, as well as the software has been rewritten with the more modern programming languages.
Thanks to the improved dynamics of the new drives and the high reliability of the new electronics, the press is much more productive with stops due to failures or malfunctions practically reduced to zero.
Together with the improvements and also thanks to the complete remote control, the result is a press that can be diagnosed and repaired (if necessary) in a short time as the components are up-to-date and easily available.