Summary: DSI Innovations completed a full servo system and PLC upgrade for a leading drink manufacturer’s Line 2 Jones Packer in just six days. The solution integrated the modern Kinetix 5700 system, reusing existing motors to control costs and ensure a rapid return to full production capacity.
Client Challenge
A leading drink manufacturer’s Line 2 Jones Packer faced challenges with an aging Allen-Bradley Kinetix 6000 Servo Drive system, which limited operational efficiency and posed reliability concerns. The project needed to replace the entire servo system with a modern Kinetix 5700 solution, including an upgrade of the existing ControlLogix PLC processor and communication cards in the PLC rack to maintain compatibility and system performance.
Existing motors had to be retained to control costs and minimize project scope, requiring careful integration and validation. The customer had a tight production schedule, which meant the work had to be completed rapidly without disrupting operations or causing extended downtime.
Our Solution
Our team was contracted to complete the project in an accelerated timeframe of just six days, leveraging a detailed project plan and skilled execution team.
The scope of work included:
- Replacing the outdated Kinetix 6000 Servo Drive system with the high-performance Kinetix 5700 system, providing increased reliability, scalability, and precision control.
- Removing and replacing the existing ControlLogix PLC processor with a new L81 processor and updated Ethernet/IP communication modules to ensure seamless data exchange and motion control.
- Incorporating updated design and CAD documentation, including marked-up drawings to show hardware changes and optimize installation strategies.
- Reprogramming the PLC, motion modules, and HMI systems to ensure that all components worked together seamlessly with the new Kinetix 5700 hardware.
- Installing a managed 8-port Ethernet switch and reconfiguring network connections to support the modern motion control system.
- DSI Innovations deployed a team of two technicians and an engineer on-site to carry out the installation, while also providing up to two days of production support post-installation to ensure a smooth transition and resolve any integration challenges.
Throughout the project, the existing motors were successfully reused, saving the client thousands of dollars and minimizing disruption to existing mechanical components.
The Results
- In just six days, DSI Innovations delivered a complete system upgrade that restored Line 2 Jones Packer to full production capability, exceeding customer expectations.
- The project’s rapid execution and reuse of existing motors controlled costs and minimized system downtime, aligning with the customer’s operational and budgetary goals.
- The new Kinetix 5700 system provided advanced motion control capabilities and a more robust control architecture, enhancing system reliability and future scalability.
- By integrating design, programming, and installation support, DSI ensured that the client’s updated system was fully functional, compliant with performance requirements, and ready for future growth.
- The project demonstrated DSI’s ability to blend technical expertise with practical execution, addressing complex upgrades under tight timelines and ensuring minimal impact on critical production processes.
Technology Used
- Allen-Bradley Kinetix 5700 Servo Drive System
- Allen-Bradley ControlLogix L81
- Ethernet/IP Communication Modules
- 8-Port Managed Ethernet Switch
- 290Amp EMC Line Filter
- K5700 Shared-bus T-Connector Kit
- DC-Bus Link & Shunt Resistors
- Power Transition and Feedback Connector Kits
- 24VDC Power Supply & Single Pole Circuit Breaker
