Legacy Machine Retrofit with Rockwell CompactLogix PLC, Panelview Plus HMI and Kinetix Integrated Motion

A leader in stamping and fabrication required a systems integrator to perform a controls retrofit on an ID Grinder that was outfitted with legacy relay-based control hardware no longer supported by the original manufacturer. The retrofit utilized Rockwell CompactLogix PLC, Panelview Plus HMI and Kinetix Integrated Motion.

CSI leveraged our experience with industrial automation platforms to evaluate a legacy grinding machine and propose a controls retrofit to modernize the system. Through discussions with our client’s maintenance and quality staff, we advised on operational challenges that could be addressed in the program design.

The ID Grinder ready for retrofit

The legacy system was evaluated and redeveloped for a Rockwell CompactLogix PLC. Given the existing system lacked a terminal, an HMI application was created, which improved operator efficiency and provided diagnostic information not previously available in the original machine configuration.

In consultation with the client’s IT department, we used the existing building network to provide remote service capabilities. Additionally, we installed FactoryTalk ViewPoint on this grinder to provide staff the means of viewing production in real-time on desktops, tablets, and personal phones.

CSI’s trained panel builders assembled the control panel and requisite hardware to complete the retrofit, maximizing the speed of project completion.

Our client has reported a dramatic improvement in operational reliability; the retrofitted machine is much easier for operators to use and for maintenance to service, and the retrofit upgrade has all but eliminated downtime due to controls hardware failure.

New panel backplane
  • Rockwell CompactLogix PLC 
  • Panelview Plus HMI 
  • AB Kinetix Servo 
  • FactoryTalk ViewPoint
  • Extended lifetime of existing infrastructure;
  • Increased production time after solving controls hardware failure;
  • Significantly improved serviceability;
  • Broadened options for controls support; and
  • Remote service capabilities.