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Retrofitting an Outdated DC Drive System

Replacing outdated DC drive systems with modern, efficient motor control solutions.

Challenge

The customer had an outdated DC Drive System on their Tandem manufacturing lines.

Complicating the issue was an old Siemens PLC & HMI control platform that the customer did not want to upgrade. ICS was asked to perform a field upgrade on the old system.

Services

Results

Turnkey upgrade (mechanical, electrical & controls) of complete Tandem line was installed and started up in less than 1 week.

  • ICS performed upgrade during weekend / Holiday timeframe to help reduce downtime.
  • New AC Drive Technology was installed on 3 extruders.
  • Open loop vector technology used on extruders.
  • PLC and HMI code was rewritten and saved for customer backups.
  • New AC motors replaced old DC motors.
  • Regenerative AC Drive installed on Capstan.
  • Regenerative AC Drive installed on Coiler.

Relevant Industries

Wire & Cable →

Benefits of rebuilding:

  • More efficient AC motors provide energy savings for customer.
  • Improved Power Factor at Plant.
  • Less downtime due to old DC motor technology.
  • Lower cost of ownership for customer.
  • Increased uptime for production line.
  • Better speed control on drives and motors.
  • Peace of mind for Owner that backup copies now existed for PLC & HMI code.
  • Less scrap was produced.
  • Reduced number of spares.
  • Training provided on system to machine operators.