Retrofit – as good as new

Control system of grinding plant for precision clay units at Pichler Brickyard in Wels modernized by AGS-Engineering GmbH

The common goal of this modernization project was to optimize production reliability while paring production and maintenance costs and improving long-term productivity.

Since replacements for the components of the old Simatic S5 control system and the disturbance-prone integrated drive controller were either hard to find, too expensive or no longer on the market, the old control system was replaced with a Simatic S7-300 with a profibus/profinet-compatible CPU 315-2PN/DP. Thanks to the system‘s clarity of design, it is exceedingly user-friendly, featuring simple, straightforward operations for fast retooling.

The new servomotors are characterized by energy efficiency and reliability, with minimal torsional backlash and such high efficiency, that their average payback time amounts to a mere 1.5 to 2 years, all the while saving on energy. With its new absolute position encoders, the system no longer needs referencing. Its disturbance propensity was eliminated, hence eradicating unnecessary downtimes. The straightforward makeup of the new hardware and the systematic software configuration all the way from e-schematic to the SPS programme and on to the drive controller enable rapid troubleshooting in case of fault.

The benefits of modernization

› reliable release levels

› time-tested interfaces

› fast troubleshooting in case of fault

› detailed fault indication

› clarity

› ease of operation

› visual layout of system components and information

› no need for reference-point approaching

› control communication

› reduced energy consumption

› state-of-the-art equipment

The modernized system once again satisfies maximum criteria in terms of reliability and longevity and is now fully prepared to meet current and future standards of industrial communication. Telediagnostics and teleservicing of the entire system, from controller to drive, can be attended to via modem or LAN router, hence giving the customer the additional benefit of further abbreviated downtimes in case of a disturbance.

Automation specialist AGS-Engineering GmbH, based at the Techno-Z Ried technology centre, implements made-to-measure solutions in the areas of automation, building services management, software, robotics, engineering and electrical planning.