Client Challenge
A leading consumer product and packaging manufacturer faced challenges with aging automation and drive systems with its Schiavi Press. The existing infrastructure, which included obsolete Eurotherm Link DC Drives, Link I/O, Microtachs, and SLC 500 PLCs, was becoming increasingly unreliable and difficult to maintain. The system’s outdated networking and operator interfaces further hindered operational efficiency and increased downtime risk.
The client required a comprehensive upgrade to modernize the press’s drives, PLCs, HMIs, and networking infrastructure while ensuring minimal disruption to production and seamless operator transitions.
Our Solution
DSI delivered a cutting-edge solution to modernize the Schiavi Press, ensuring improved reliability, performance, and maintainability. Key aspects of the solution included:
- Drives and Motor Upgrade:
- Replaced eight obsolete Eurotherm Link DC Drives and Link I/O with modern Parker SSD LinkNET DC Drives and PLC-based I/O.
- Upgraded seven legacy Microtachs on DC motors to motor-mounted encoders with new cabling.
- PLC and Network Modernization:
- Converted the existing SLC 500 PLC system to a CompactLogix 5069 platform, utilizing Flex I/O in the Unwind, Rewind, and Operator Station panels over Ethernet communications.
- Replaced outdated LinkNET networking with off-the-shelf Ethernet technology and cabling to provide a robust and scalable network architecture.
- Operator Interface Upgrades:
- Replaced four Eurotherm Link Touchscreens with TS8000 6” Ethernet-based HMI panels, improving operator usability and system responsiveness.
- Upgraded the existing Wonderware system to a Windows 10 computer running the latest Wonderware software, modifying the tag database to integrate seamlessly with the new CompactLogix PLC.
- Electrical Design and Implementation:
- Designed the new DC drives, I/O systems, and network architecture using AutoCAD, ensuring compliance with industry standards.
- Converted existing drive configurations, PLC programs, and Wonderware configurations to align with the upgraded system.
- Installation and Support:
- Installed, wired, and tested all new components, including eight DC drives, seven encoders, new encoder cables, PLC, and I/O systems.
- Conducted system checkout, start-up support, and production assistance, ensuring a smooth handoff to operations.
- Provided comprehensive operator and maintenance training to minimize the need for retraining and ensure ongoing system success.
The Results
DSI’s upgrade transformed the Schiavi Press, delivering:
- Improved Reliability: The replacement of outdated components with modern drives, PLCs, and encoders significantly reduced system downtime and improved maintainability.
- Enhanced Performance: The upgraded Ethernet-based network and Wonderware integration streamlined system communication, enabling faster and more reliable operations.
- Operator Continuity: Configuring local operator stations to replicate the existing interface minimized disruption, allowing operators to seamlessly transition to the upgraded system.
- Scalable Infrastructure: The use of scalable, off-the-shelf technology ensured that the press is well-positioned for future upgrades and expansions.
DSI’s comprehensive solution provided the client with a state-of-the-art control system, restoring the Schiavi Press to peak performance and ensuring its reliability for years to come. The success of this project highlights DSI’s ability to modernize aging systems while minimizing operational impact and maximizing client value.
