Summary
An obsolete PLC failed, and the original program could not be recovered. A new PLC and HMI were installed with new programming to restore original function.
Key Benefits
- Maintainable control system
- Improved user interface
- Fast turnaround
- 75% cost savings compared to OEM quote
Technologies used
- Allen Bradley Micro 800 PLC
- Allen Bradley PanelView 800 HMI
The Breen Machine Solution
A bag filling and sealing machine was running on obsolete hardware. When the 30-year-old PLC died, the program could not be recovered. There was minimal documentation of the system design or function. The OEM would only consider a complete control system retrofit, which wasn’t cost justified for this limited use machine, so the challenge was to select and program a new PLC and HMI, starting with almost no information, in a cost and time sensitive way.
Breen Machine worked closely with the customer to understand the function of the machine and develop a plan. New parts were selected to replace the PLC, operator interface, and a few peripheral components. Breen Machine wrote the new program while the parts were shipping so installation could happen as soon as they arrived. The install and program debug took a day and the customer was able to resume production. Breen Machine offers the personal touch and creative solutions that support small manufacturers. To quote this customer: “The [OEM] wanted $20,000 to replace it. [Breen Machine] came in for under $5,000 and got it done 3 times faster than anything they could’ve done. It was great!”
Do you have aging control systems? Let us know how we can help.
About the Author
Jon is an engineer, entrepreneur, and teacher. His passion is creating and improving the systems that enhance human life, from automating repetitive tasks to empowering people in their careers. In his spare time, Jon enjoys engineering biological systems in his yard (gardening).
