Projects / 05
Renew the control
without scrapping the mechanics.
The skeleton was sound; the brain could not be spared. We renewed control and safety in stages without stripping the mechanics.
Project
Custom Machine Control Retrofit
The skeleton of the custom machine in Konya was running. When a card could not be found, the stop stretched; the software waited for the person who wrote it.
We did not enter with a new-line promise. We opened the door first. I/O, spares, and the operator’s real reset were written into the inventory.
Need
An old brain slows a sound body.
The request arrived as “a new machine.” The real need was to shorten intervention time.
01
Controller cannot be spared
Mechanics run; when a card cannot be found, the stop stretches.
02
The code belongs to one person
Tags are scattered, no comments. The next intervention waits for the author.
03
Safety is patched
Gate and lock were added over the years; reset was rediscovered every time.
Scope
What locked on this job.
- 01
Cabinet, I/O, and software inventory
- 02
PLC and HMI vocabulary translation
- 03
Servo / axis update
- 04
Safety gate and reset sequence
- 05
Staged FAT and staying in production
Application
Cover, cable, axis.
03 frames
01 / 03
Approach
Inventory, translation, staging.
The new architecture was not written by ignoring the old cabinet. Which unit would go silent, and when, was planned.
01
Reading
Cabinet, I/O, and the operator reset were written in place.
02
Translation
Old names moved into the new vocabulary. The servo speaks to the existing axis.
03
Staging
It was not a weekend of “everything changes.” Handover ran through overlapping stops.
On site
The skeleton stays; motion is readable.
Axis and safety were updated to speak with the existing frame. The lock-in inside the pendant ended.
Services
Services used.
- 05Review
Retrofit
Sound mechanics do not have to be stripped out.
- 03Review
PLC & SCADA
Control software must belong to the night shift as well.
- 02Review
Line Automation
A running station is not a running line.
Result
Strip-out is not the default step.
We do not cut downtime as a percentage. Delivery is a control that has become readable.
Completed equipment
PLC, HMI, and safety were renewed on the existing skeleton.
Integrated system
Servo and reset can be tied to the line sequence.
Commissioned solution
The tag vocabulary stays in a language the next engineer can also read.
Projects
Talk with the engineering team.
A new line, an existing cell, or an ageing cabinet. Scope comes from the work on your line, not from a catalogue.