Machine retrofit and modernization
New control infrastructure for mechanically sound machines: PLC, I/O, communication, cabinets and safety.
Many machines are still mechanically in good condition, but their control system is obsolete, spare parts are hard to obtain and nobody can maintain the program any more. With a retrofit we keep the machine and move its control to a modern, maintainable platform.
The scope is defined for each project: sometimes it is enough to replace the PLC and I/O and transfer the existing program, while in other cases the electrical cabinets, drives, sensors and the complete safety system are renewed as well.
What it includes
PLC system replacement
Migration from obsolete PLCs to modern control platforms.
Distributed I/O and field level
Connection of field inputs and outputs via new distributed I/O stations.
Communication modernisation
Migration from legacy networks to Ethernet protocols (e.g. EtherNet/IP).
Adaptation of existing software
Transfer of the existing program to the new architecture or rewriting it.
Electrical cabinets and drives
Replacement of control cabinets, frequency/servo drives and operator panels.
Safety system renewal
A new safety controller and safety equipment in the field.
Where it is used
- Machines with obsolete or unavailable PLCs
- Industrial furnaces and process lines
- Escalators and conveyor systems
- Machines without technical documentation
How we work
- Review of the existing system – machine operation, control, program and field equipment.
- New architecture – what is kept, what is changed and what the new control and communication structure looks like.
- Cabinets and field level – installation of new cabinets, I/O stations and connections, with a short planned downtime.
- Software adaptation – transfer or rewriting of the program for the new platform.
- Testing and recommissioning – on-site verification and return of the machine to production.
Benefits for you
- The mechanically sound machine stays, the control system becomes modern
- Available spare parts and support for the new equipment
- Shorter downtime thanks to a planned changeover
- Option to expand and connect to the rest of the plant
Equipment and technologies
Components we most often use in such systems – all also available as individual supply:
Related projects
Automotive glass productionModernisation of a lamination furnace control system
Automation overhaul of a windscreen lamination furnace: the existing CS1 and DeviceNet infrastructure was replaced by the Sysmac platform with distributed I/O on an EtherNet/IP network.
View project ›
Public transport – railway stationAutomation of heavy-duty escalators
Complete renewal of the electrical cabinets, automation and safety control of escalators: Sysmac, distributed I/O, NX-SL3300 safety controller and Safety over EtherCAT.
View project ›Let's talk about your project
Describe the machine, line or process – we will get back to you with a proposed solution and an estimate of the scope of work. For new projects and upgrades of existing systems.
info@meridiangroup.rs · +381 66 60 60 497
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