Why You Should Modernize Your PLC Control System
Another advantage of upgrading to a modern controls platform is the significantly increased performance. The new series of controllers have more processing power and can be connected to modern IT networks. Furthermore, new PLCs are easier to integrate with MES and ERP systems, providing the ability to collect data, generate detailed production reports, and monitor equipment in real-time.
New controls hardware is also more flexible with the ability to support a wide range of I/O and communications modules. These modules make it easier and more cost effective to scale a new system to any manufacturing environment or application.
Modern PLCs also come with new software programs that can provide more diverse feature sets and enhanced graphics for HMIs. The new software programs also simplify diagnosing and troubleshooting system faults.
Consulting a Control Systems Integrator
At Process Solutions, we offer start-to-finish PLC migration services. We will conduct an on-site assessment, develop a migration plan, design and build the new system, and handle all the on-site start-up and commissioning services. Process Solutions will also go the extra step to ensure your new system is optimized to improve the efficiency and performance of your operations versus just replacing the legacy system with new parts.
Phased Migration Approach
- The first phase of the process consists of converting the old PLC-5 program code to operate on the new controls hardware. With automated software code conversion tools available, this phase is usually straightforward and quick to complete. Once the code has been converted, we put it through our standardized testing procedure to ensure proper functionality and to eliminate any bugs or errors.
- Once the program code has been converted and thoroughly tested, we move on to replacing the PLC-5 controller with a new processor and I/O cards. Whenever possible, we take care to preserve the existing field wiring to reuse with the new controller. By reusing the existing field wiring, we can save a significant amount of time on labor and costs.
- With the new PLC in place, we can replace any old HMIs with new HMI models that provide options for enhanced graphics and expanded feature sets.
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