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Outdated DC Drive System

Is it possible to update a DC drive system without updating an old PLC & HMI control platform?

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The customer had an outdated DC Drive System on their Tandem manufacturing lines.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

Integrity Control Services
Automation implementation, integration, and maintenance for any industry.

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