We’re your source for automation news. Keep up with the latest industry updates and E Tech employee spotlights, as well as tips and guidance from our manufacturing experts.
A PLC-5 to ControlLogix conversion within 48 hours helped improve control and visibility for a food manufacturer’s conveyor system.
Challenge
Challenges arise when hardware and software become outdated. This was the case for a leading food manufacturer who needed modernized controls for their warehouse conveyor system. The existing Allen-Bradley PLC-5 hardware was obsolete and lacked modern communication protocol. The conveyor system also lacked HMIs to monitor processes, identify problems, and visualize data. Because of this, the customer sought the help of E Tech Group, an E Tech Group company, to upgrade their Allen-Bradley PLC-5 to the latest Rockwell Automation ControlLogix processor, integrate AVEVA InTouch HMI stations, and connect devices over an EtherNet/IP communication network.
Solution
E Tech Group was challenged to migrate the PLC system within 48 hours of planned downtime. E Tech Group worked closely with the customer to understand their existing system in detail and identified potential challenges that could occur before the PLC conversion. After this step was completed, E Tech Group proceeded with the Allen-Bradley PLC-5 to ControlLogix migration, overseeing the installation and testing. E Tech Group converted the existing PLC-5 logic to its Logix equivalent and connected the new ControlLogix processor to distributed, remote, and POINT I/O racks via EtherNet/IP communication network. Then the project team configured and connected devices with AVEVA InTouch HMI to provide conveyor line operators with better visualization capabilities.
Results
This upgrade provided the food manufacturer and its operators with greater control and visibility over their conveyor system, enabling efficient fault detection, improved PLC and HMI communication, data acquisition, and technical support from the manufacturer. With this migration project completed, the customer minimized their risk of downtime, enhanced conveyor performance, and strengthened their network communications.
The Automation Group acquisition expands E Tech Group’s market-leading positions in the automation of Life Sciences, Food and Beverage, Consumer Packaged Goods, and Data Center industries. While adding additional resources and expertise in cybersecurity and big data. Get to Know Automation Group (AG): Automation Group, an E Tech Group Company, is a leading provider of automation services. AG’s specific product and application experience has led them to the implementation of complex automation solutions across North America. They create a best-in-class technology path for America’s manufacturers by integrating proven automation, networking, and virtualization solutions. Headquartered in Modesto, California with additional resources located across the United States. Automation Group, an E Tech Group Company, has collaborated with over 1,000 clients, including numerous high-profile businesses spanning multiple industries, such as prominent companies in automotive, CPG, food and beverage, among others. With core values of- innovation, dedication, expertise, people-focused, and trustworthiness, like E Tech Group, they are proud to stand behind their work and have 90% repeat clients! With a wide range of capabilities from Cybersecurity, Virtualization, Automation Design, Networking, and Big Data, the AG team can partner with a client from any point in the journey. This collaborative partnership approach is what makes AG a natural fit for the E Tech Group team. E Tech Group strives to be the Main Automation Partner for our clients. We thrive in investing in the client’s business objectives and helping them reach both their short-term goals and planning for future success. We are excited to have Automation Group join the E Tech Group team and to see how both teams will complement one another and become BEYOND great together. Capabilities Code Development Automation Design Networking Virtualization Process Big Data Cybersecurity UL508A Control Panels Industries Distribution and Logistics Food and Beverage Electric Vehicles Entertainment Water and Wastewater … Continued
We were honored to have THREE presentations during this year’s Rockwell Automation Fair. We were honored to have THREE presentations during this year’s Rockwell Automation Fair. E Tech Group team members presented on: We were also excited to exhibit and engage with colleagues, clients and prospective partners at our booth on Wednesday and Thursday. We hope everyone had as wonderful a time as we did, and we look forward to seeing you all again next year! And not to be overlooked, we had a blast hosting our own Happy Hour at Lord Hobo on Wednesday evening. Thank you to our partners at Rockwell for a great week of education, connection and DISCOVERY!
PLC-5 to ControlLogix Migration Supports Greater Uptime for Global Spice Supplier
A global supplier of spice ingredients needed to upgrade their Allen Bradley PLC-5 system. E Tech Group was recruited to modernize their obsolete PLC system to a more IIOT-friendly platform.
The Project: Remove Production Constraints with Complete Control System Upgrade
A global supplier of spice ingredients needed to upgrade their 25-year-old Allen Bradley PLC-5 system. The outdated platform was experiencing constraints and was limiting network connections. The client was seeking a system integrator that could provide timely PLC migration support using the latest technology available.
Automation Group, an E Tech Group Company was recruited to modernize their obsolete PLC system to a more IIOT-friendly platform. Automation Group, E Tech Group’s most recent acquisition, is a leading provider of automation services. They’ve worked with over 1000 clients across North America, implementing advanced control system solutions tailored to each facility’s unique challenges.
The Solution: Implement an Integrated, IIoT-Compatible Control System
E Tech Group automation professionals reverse-engineered the customer’s legacy system and analyzed existing diagrams to identify potential risks to obtain detailed information on device and wiring configurations. This step was crucial to improve control system performance and understand their control environment before moving to the design phase.
As a leading Rockwell Automation system integrator and CSIA-certified automation company, we developed a simplified migration plan using the latest technologies. We converted all networks to Ethernet/IP communications, upgraded the client’s PLC-5 system to ControlLogix and consolidated FactoryTalk View SE screens, making it easier for plant personnel to operate the system.
The Results: The First Step in a Digital Transformation
The global spice supplier’s upgrade from PLC-5 to ControlLogix was completed on schedule and improved performance, greater uptime, and a more user-friendly interface for the client’s PLC system. This upgrade project was a crucial step in the client’s digital transformation journey.
Our recent addition, Automation Group, an E Tech Group Company, designed and implemented this creative automation system solution. For more information on this control system upgrade, visit their website to read the complete case study.
