Electrically Faulty machine, re-design & re-programming

"A customer tasked us with identifying and resolving recurring VSD faults in one of their large production plants. Upon investigation, we discovered that the aging machine suffered from redundant hardware, poor wiring, and a suboptimal logic program.

To address these issues, we removed all redundant hardware and replaced the faulty VSDs and controls with modern equipment. The new hardware was strategically relocated further away from the process to protect it from dust and heat exposure. Additionally, we replaced multiple outdated PLCs with remote I/O and rewrote the program using a Codesys PLC, consolidating control from four PLCs into one. This significantly reduced system complexity and allowed us to replace cumbersome multi-core cables with a single CAT5 connection.

Since completing the project, the frequent errors and faults that previously overwhelmed the customer’s maintenance staff have been completely eradicated, resulting in a far more reliable and efficient system."