Is there a discontinued B&R system in your machine? Maybe it’s the time for an upgrade?
Quite often the machine is in good condition when looking at the mechanics. The limiting factor of lifecycle is very often discontinued automation system where spareparts are no longer available. It’s however possible to extend the machines lifecycle by upgrading the automation system.
It’s possible to
Upgrade to older B&R system to the latest hardware to secure the spare part supply.
Convert the old PLC software to latest Automation Studio and run it on the latest controller hardware.
Add new functions which are offered by the new system
Example of a system upgrade project: B&R 2005 -> X20
Production machine is delivered in 2004 by german machine manufacturer. The machine has B&R 2005 control system which is already discontinued by B&R and it’s getting difficult to find spare parts.
To upgrade the system, the following steps are taken
Analysis
Listing the system components
Software / source code analysis
Selection of replacement components
Electrical design
Modification of the existing electrical drawings
Communication diagrams
IO-module connection diagrams
Modification and update of the software
PLC program will be converted to the latest Automation Studio version
Necessary program changes are done
Hardware configuration will be adapted
IO mapping to the new hardware will be done
Verify all software functions
Commissioning without interfering the production
If needed, the new system can be installed parallel to the old one
It’s easy to switch back to old system if needed
Final exhange of the system will be done only after new system is fully tested and functional
System upgrade can be done outside the production hours during weekends or even night time
Testing
All system functions are tested in real production envinronment to verify 100% compatibility
There will be certain time of so called babysitting when the production is started with the new system. Typically 2-3 days production.
