Controls & Drive System Upgrade Case Study
Task
A packaging supplier needed to modernize the controls and drive systems during a scheduled shutdown. The existing PLC had become obsolete, creating challenges for long-term reliability, maintenance, troubleshooting and future support.
Solution Services was asked to replace the outdated PLC with a new Allen-Bradley ControlLogix PLC, incorporate a new Ethernet communications protocol into the system design, and replace the existing DC motors and drives with new AC motors and drives.
Because the work had to be completed during a planned shutdown, timing, coordination and execution were critical. The customer needed a partner who could manage the electrical, mechanical and engineering requirements together while minimizing downtime and ensuring the line was ready to return to operation on schedule.
Execution
Solution Services brought together its electrical, mechanical and engineering divisions to plan and execute the upgrade as an integrated project. Before work began, the team reviewed the existing system, identified the components that needed to be removed or replaced, and coordinated the sequence of work to make the most efficient use of the shutdown window.
During the scheduled shutdown, Solution Services removed the obsolete PLCs, existing DC motors, drives, motor mounts, wiring and related equipment. The team then built and installed new motor mounts to support the upgraded AC motors and drive system.
Once the mechanical components were in place, the electrical team installed new conduit and wiring, set the new PLCs, and completed all electrical, control and communication terminations. The upgraded Ethernet communications protocol was incorporated into the system design to support improved connectivity and modern controls communication.
After installation, the team tested connections, verified communication, checked system functionality and aligned the motors to support reliable operation. Throughout the project, managers from each division provided the customer with daily updates, communicated clearly about progress and quickly addressed any questions or needs that came up during the shutdown.
What the Project Included
The project required close coordination across multiple disciplines, including:
PLC removal and replacement
Allen-Bradley ControlLogix installation
Ethernet communications integration
DC motor and drive removal
AC motor and drive installation
New motor mount fabrication and installation
Conduit and wiring installation
Electrical, control and communication terminations
Connection testing and motor alignment
Conclusion
Solution Services completed the upgrade on time and within budget. The customer received a modernized controls and drive system designed to improve reliability, maintainability and future support.
The project also demonstrated the value of Solution Services’ integrated approach. By coordinating electrical, mechanical and engineering teams under one project plan, Solution Services helped reduce complexity, streamline communication and keep the shutdown work on schedule.
The successful completion of the project reinforced Solution Services’ ability to support complex industrial upgrades during critical shutdown windows while delivering a professional, well-coordinated customer experience.
Your Problems Are Our Problems
At Solution Services, we understand that maintenance challenges don’t just impact equipment; they impact your people, production goals, and bottom line. We approach every project with the mindset that your problems are our problems, and we work with the same urgency and commitment as if it were our own facility on the line.