A wood products manufacturer operating three identical flaker machines needed to reduce lifecycle risk in a critical hydraulic motion application. Their existing Allen-Bradley™ hydraulic motion servo module (1756-HYD02) had reached end-of-life (EOL). It was no longer supported, creating a significant risk if the hardware ever failed.
This was not a quality issue with the original platform; it had performed well over its lifecycle. The challenge was that continued operation was now constrained by obsolescence and parts/support availability.
ICS replaced the obsolete solution with a Delta Motion RMC controller, maintained the machine’s original functionality and safety integrity, and improved throughput by optimizing cycle performance.
“Our goal was to remove lifecycle risk without disrupting the machine’s proven operation—and then look for opportunities to make it run better.” - ICS (Engineering Manager)
Though machines were still operational at the time we were contacted, the company’s controls platform was aging rapidly, and the customer was receiving lifecycle notices indicating that the PLC and associated components were out of date.
The biggest concern was the hydraulic motion servo hardware:
In short, the system didn’t need to be “fixed” because it was broken. It needed to be updated because it was becoming unsupported.
We worked with the customer to modernize hydraulic motion control while minimizing disruption to production and reducing long-term support risk. Our team delivered the upgrade through a focused scope of work:
For this upgrade, we needed a solution that could replace an end-of-life 1756-HYD02 with minimal disruption and long-term confidence. The Delta Motion RMC was the right fit because it provides:
It is also aligned with Rockwell’s migration direction and backed by strong vendor support and long-term availability, which is the best reason for moving away from obsolete hardware.
Our customer achieved two wins: a supportable solution for an end-of-life hardware problem, and a measurable increase in productivity.
ICS reduced cycle time by improving carriage return timing and increased throughput:
Controls obsolescence is a normal part of industrial automation. End-of-life notices are about product lifecycle and manufacturer support—not an indictment of the equipment’s original performance. The value of an upgrade like this is reducing downtime risk and keeping critical machines supported for years to come.
If you’re running an Allen-Bradley 1756-HYD02 (or other end-of-life motion hardware), the next failure could be the one that turns into extended downtime, as parts and support may no longer be available. We can help you evaluate your current setup, outline a migration path, and execute a low-disruption upgrade that keeps your machine’s proven operation intact.
Talk with our team about:
Whether you’re proactively upgrading end-of-life controls or responding to an unexpected failure, ICS provides responsive industrial automation support, including 24/7 field service.
Call ICS today or send us a message to get started.
Integrity Control Services
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