Legacy Controls Upgrade:
Bringing 1960s Takeup Machine into the 21st Century
INTRODUCTION
UPGRADING OUTDATED EQUIPMENT TO RESTORE EFFICIENCY, FLEXIBILITY, AND CONTROL
A long-time client of Cleveland Automation Systems® (CAS) was experiencing speed and control issues with their Winding/Spooling Takeup machine. The legacy control system for this machine was designed in the 1960s and could not adjust acceleration, deceleration, and variable control. (Check out that date stamp from 1966!)
BEFORE
AFTER
Outdated systems like these present significant challenges, including component failure and equipment downtime, which made a Legacy Controls Upgrade imperative. Moreover, the client needed the capability to run different speeds and configurations for various products.
If left unchecked, these issues could lead to financial losses, missed deadlines, reduced output, and potential reputational damages. Cleveland Automation Systems did a thorough assessment and determined that a new Legacy Controls Upgrade was needed.
The outdated system was modernized by introducing an analog output, variable speed control, and various setpoints utilizing a PLC and HMI combination unit. This Legacy Controls Upgrade increased scalability, productivity, and system accuracy, significantly improving product control and quality.
Solution for Legacy Controls Upgrade
To address the client’s needs, CAS designed a system capable of traversing left and right while rotating a spool at variable speeds, taking up product from an upstream process. This Legacy Controls Upgrade ensured that the mobile machine could adapt to multiple speeds and processes, providing more flexibility for the client.
CAS incorporated a dancer mechanism for variable output systems and turned the machine into a standalone takeup system. In standalone mode, the operator can input a rotational speed setting for the rotation axis, driving at the preset speed and pulling product at a constant torque.
Human Machine Interface (HMI) Integration for Legacy Controls
The original system used a legacy DC control circuit with manual adjustments. After conducting our signature site assessment, we determined that incorporating an HMI would better serve the client’s needs.
Adding an HMI allowed operators to see speed readout in real-time, adjust the direction of travel, and alternate modes of operation. This simple addition empowered the customer to have greater control and standardized operations.
Benefits of HMI in Legacy Controls Upgrade
Before the upgrade, operators would estimate settings using a physical potentiometer switch, requiring trial and error during setup. With the HMI, operators can now input a preset speed from 0.00 to 100.00% via the touchscreen interface, which is crucial for running different products at various speeds. This data is now recorded in the recipe management and is part of the startup process.
System Requirements Overview for Legacy Controls
Upgrading the legacy controls of a 1960s takeup machine presented a unique challenge due to the need to modernize the equipment while maintaining its original mechanical integrity. The primary goal was to enhance the machine’s functionality and performance to meet current production demands without compromising its proven reliability.
Cleveland Automation Systems’ comprehensive assessment of the existing control system allowed them to develop a strategic plan to integrate the modern technology needed to extend the machine’s operational life and improve its efficiency based on the following essential requirements and specifications.
Essential Requirements and Specifications for Legacy Controls Upgrade
PID Control
Including Proportional-Integral-Derivative (PID) control significantly enhanced the precision and stability of the machine’s operation. Using PID control allowed the upgraded system to maintain optimal speeds and torque, thus minimizing fluctuations and enhancing product consistency. This precision was a significant improvement over the older system, which relied on less sophisticated manual adjustments.
Analog Inputs/Outputs
The introduction of analog inputs and outputs provided a more refined level of control over the machine’s operation. This allowed the system to respond dynamically to changes in load and speed requirements, enabling smoother transitions. Unlike the previous setup that relied on rudimentary, binary inputs, the analog controls allowed for incremental adjustments, providing better performance tuning and flexibility.
Variable Speed Control: 0-600 FPM range for various spool sizes
The implementation of variable speed control allowed for speed adjustments within a range of 0-600 feet per minute, accommodating different spool sizes and production requirements. This flexibility ensured operators could precisely adjust the speed based on the product being run, which was impossible in the legacy system where fixed speeds limited production efficiency and versat
Dancer Integration
The integration of a dancer mechanism enhanced the machine’s ability to maintain consistent tension on the spooled material, which was critical for quality control. This feature allowed the system to automatically adjust to variations in tension, which previously had to be manually controlled or approximated. This enhancement ensured smoother production runs and reduced the chances of material defects due to inconsistent tension.
DC Motor Control
The addition of modern DC motor control enabled smoother and more efficient motor operation compared to the outdated legacy controls. This improved the ability to manage rotational speed and torque with greater precision. The modern DC motor controller provided more efficient energy use, improved reliability, and reduced wear and tear on components, thus extending the equipment’s operational lifespan.
Hardware for Legacy Controls Upgrade
Cleveland Automation Systems (CAS) led the modernization of this legacy control system, selecting a compact, all-in-one solution to meet the specific needs of the 1960s takeup machine. CAS chose a robust control unit that offered the versatility required for small, standalone applications, delivering a highly cost-effective upgrade while improving operational efficiency.
The upgraded system, which features real-time monitoring and easy-to-use controls via an integrated HMI touchscreen, enhanced both performance and accessibility for operators. At CAS, we ensured the upgrade came in under $1,000 USD, delivering exceptional value without compromising functionality or reliability.
In partnership with MSITec, CAS seamlessly integrated the hardware and ensured its optimal performance. MSITec’s support throughout the project further enabled the smooth implementation of this advanced control solution.
Software for Legacy Controls Upgrade
The software aspect of the modernization was equally critical, and CAS used an intuitive platform to design and configure the control system to the client’s specific requirements. The software enabled efficient programming and provided a flexible environment for customization, allowing CAS to fine-tune the control logic and optimize the machine’s performance.
This software platform empowered us at CAS to enhance machine functionality, enabling real-time adjustments and ensuring that the system was adaptable for future needs. The result was a modernized control solution that improved both the machine’s longevity and operational flexibility.
Our expertise in integrating both hardware and software ensured a comprehensive upgrade that supported the client’s production needs for years to come.
Outcomes and Benefits of Legacy Controls Upgrade
The upgraded control system brought the 1960s takeup machine into the 21st Century, resulting in remarkable improvements across several key areas. Integrating the HMI allowed real-time adjustments, significantly enhancing operator control and standardizing operations. This modernization not only increased the machine’s scalability but also improved overall productivity and system accuracy.
Key Positive Outcomes:
- Increased Scalability: The new control system allowed the client to handle varying production demands more effectively, accommodating a range of speeds from 0-450 feet per minute and recipes for various products.
- Enhanced Productivity: The ability to input precise settings and monitor real-time data led to a smoother and faster setup process, allowing setup time to be reduced to less than 5 minutes.
- Improved System Accuracy: The precise control provided by the new system reduced errors and inconsistencies, leading to better product quality and fewer rejects.
- Real-Time Adjustments: Operators could now make on-the-fly adjustments, optimizing the production process and responding swiftly to any issues.
- Standardized Operations: The introduction of preset speed settings and recorded data into the SOP ensured consistency and reliability in operations.
- Cost Savings: The increased efficiency and reduced downtime translated into significant cost savings, improving the client’s bottom line.
- Future-Proofing: The updated system is adaptable to future advancements such as IIoT integration, AI-driven predictive maintenance, and remote monitoring, ensuring long-term value and relevance.
Customer Benefits from Legacy Controls Upgrade
- Increased Productivity: Enhanced efficiency and reduced setup times allowed higher output and improved overall performance.
- Improved System Accuracy: Precise control settings minimized errors and maintained consistent product quality.
- Enhanced Product Control and Quality: The ability to fine-tune operational parameters ensured optimal product handling and quality.
- Greater Operational Control: Operators gained greater insight and control over the machine’s operations, enabling quicker adjustments and better process management.
Transform Your Legacy Systems with Cleveland Automation Systems
This case study highlights how CAS effectively upgraded a legacy control system, delivering significant operational improvements and cost savings to the client. If you’re facing similar challenges with outdated control systems and want to bring your operations into the 21st Century, explore our System Upgrades & Retrofits services and see how Cleveland Automation Systems can provide tailored solutions to modernize your equipment. We’re here to help you achieve enhanced productivity, improved system accuracy, and greater operational control.
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About the Author: Rylan Pyciak
Rylan Pyciak, CEO of Cleveland Automation Systems®, is a Systems and Control Engineering graduate from Case Western Reserve University. With expertise in PLCs, robotics, and industrial engineering, Rylan leads CAS in delivering innovative automation solutions. Passionate about mentoring future trades professionals, he combines technical knowledge with a commitment to fostering sustainable growth in manufacturing.