As systems age and components become obsolete, manufacturers are looking for cost-effective methods of preserving their hardware and programming investments while extending component life and improving the manufacturing process.
Says Schneider Electric automation product manager, Linda Eales: "Introducing our Telemecanique Automation Services, the latest enhancement to our industrial automation services, is to ensure that our customers can keep their systems running at peak capacity. It is crucial to recognise that while automation suppliers like ourselves are experts at providing new systems, sometimes our best solutions have to do with older installations.
"Our Modicon Advance Program, for example, can greatly simplify the process and reduce the cost of migrating from legacy equipment to state-of-the-art technology. If users have legacy equipment, they are probably worried about breakdowns, downtime and high maintenance costs, not to mention the threat of product obsolescence.
"We can address all those concerns with upgrades, all of which means improved production and efficiency, lower repair costs, reduced downtime and increased reliability. The Modicon Advance Program lets the user choose what to update and when.
"Users can upgrade their systems without having to completely rewrite the software or replace all the hardware, keeping systems running at peak capacity, whether they contain Telemecanique, Modicon or Square D automation products."
The Modicon Advance Program is a simple process to update legacy systems based upon specific needs and requirements, allowing for the selection of the right level of upgrade for processors, software and I/O points.
Three programes are offered, partial migration, incremental migration, and total migration.
When implementing partial migration, there is a single-step upgrade of the processor to a Modicon Quantum, while retaining current ladder logic software. This one-step process gives the option to migrate the processor to a more modern Quantum platform while retaining existing 984LL software for a longer-term.
This partially addresses many legacy platform concerns, such as improved processor reliability, availability of MRO spares, increased communication throughput and options, faster speeds, and the opportunity to expand. It also means a smaller initial investment.
Incremental migration deploys a phased approach consisting of three simple steps to migrate a legacy platform to a new Modicon Quantum processor, convert current software, and upgrade I/O-based upon whatever timeframe is required.
This is a three-step process. In the first step, the processor is migrated to a Quantum PLC. In the second step, the user has the option to convert 984 Ladder Logic software to the universal IEC 61131-3 format.
Step three involves the updating of the remote I/O and wiring. Steps two and three can be conducted in reverse order if preferred.
An incremental migration does mean a smaller initial investment - and potentially the user can finance this using the maintenance budget.
This does mean that the user can manage an upgrade investment based on individual schedule and budget needs.
This is a comprehensive solution that address such concerns as improved processor reliability, the availability of MRO spares, increased communication throughput and options, faster speeds, the potential to expand functionality such as add machine functions or diagnostics, and the opportunity to increase machine capacity and throughput.
User can also opt for a total migration, which is a complete, single-step migration to a modern platform that consists of a Modicon Quantum processor, IEC-based Unity software, and upgraded I/O.
In this one-step process, the processor is migrated to a Quantum with conversion of 984 Ladder Logic software to the universal IEC 61131-3 format and update of the remote I/O and wiring.
The benefits of a total migration are exactly the same as those for an incremental migration.
Concludes Eales: "We say that our users can update their whole plant - without having to update their whole plant! We believe that this type of upgrade is becoming increasingly market-driven as companies have to continually improve their output and costs - without compromising quality - in order to remain competitive".
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