The control system upgrade required the migration of legacy SLC™ controllers to Allen-Bradley® ControlLogix® to help reduce maintenance costs and allow for increased flexibility on production lines. While justifying the risk and expense of control system upgrades may initially seem like a challenge, investing in modern technologies that leverage the Industrial Internet of Things helps manufacturers realise the benefits of smart manufacturing.
As Jonathan Footman, solutions architect, Rockwell Automation, explained, “The more connectivity you have across the plant floor helps implement the technology to enable smart manufacturing and progress in the journey towards a Connected Enterprise.”
Keeping the Plant Running
To keep the plant running, Arnott’s leveraged the inherent flexibility of the Rockwell Automation Integrated Architecture® system to undergo a staged migration to the new controllers.
The ControlLogix control system offers modular architectures and a range of I/O and network options. Tight integration between the programming software, controller, and I/O modules, reduces development time and costs at commissioning and during normal operation.
To help reduce engineering time, SAGE used existing SLC I/O in the first stage and subsequently added some Ethernet Point I/O and Flex I/O on DeviceNet. The RSLogix™ Project Migrator tool was used to install the ControlLogix controllers with ease.
“While the majority of the plant uses Ethernet, there is still some equipment communicating through DeviceNet and DH+™ so by using ControlLogix, any potential integration issues were overcome because the controller is compatible with all three networks. This flexibility allowed the upgrade to be performed in a staged manner as opposed to having to perform the whole upgrade in one go,” explained Footman.