Complete Automation Retrofit of Metal Finishing Production Line

A metal finishing company faced critical challenges with their aging production line control system, including obsolete components, inaccurate documentation, and unavailable spare parts. Our team successfully executed a complete automation retrofit within a tight 3-week production shutdown, modernizing the entire system with state-of-the-art Siemens automation technology and implementing 27 variable frequency drives for significant energy savings and improved process control.

Achtergrond van de klant & de uitdaging

The Situation

The client operates a metal finishing production line consisting of:

2 industrial ovens
1 pretreatment tunnel with spraying system
1 degreasing bath
2 chain conveyors

Critical Problems

The existing control system had reached end-of-life with several critical issues:

Obsolete Control Cabinet: The electrical cabinet was extremely outdated with components no longer supported by manufacturers
Inaccurate Documentation: Electrical schematics no longer reflected the actual installation, making troubleshooting nearly impossible
Parts Unavailability: Critical spare parts were discontinued, creating significant operational risk
Reliability Concerns: Frequent breakdowns and maintenance issues affected production schedules
Energy Inefficiency: Fixed-speed motors and pumps consumed excessive energy
Limited Control: Lack of modern process control and monitoring capabilities

The client needed a complete modernization to ensure continued production reliability and improve operational efficiency.

De oplossing

Pre-Study Phase

Before implementation, our team conducted an extensive pre-study to:

Document all existing electrical cabinets and control systems
Reverse-engineer the actual installation versus outdated schematics
Map all I/O points, motor connections, and safety circuits
Develop completely new electrical schematics for the modernized system

Automation Architecture

We designed a comprehensive automation solution based on modern, reliable components:

Control System:

Siemens S7-1512SP PLC – High-performance controller for complex process coordination
HMI MTP Unified 15″ – Modern touchscreen interface for intuitive operation
2× IFM AL1102 IO-Link Masters – Advanced sensor integration and diagnostics
Rittal RiLine 800A Railsystem

Key Features Implemented

Variable Speed Control: 27 motors equipped with VFDs for optimized operation
DOL Motor Control: 30+ auxiliary motors controlled via Siemens contactors
Modulating Burner Control: Precise temperature management in both ovens with 2 modulating burners per oven
Automatic Pressure Regulation: Tunnel spraying pumps with intelligent pressure control
Process Visualization: Real-time monitoring and control via modern HMI

Uitvoering

Project Timeline

Pre-study and Engineering: 4 weeks
Manufacturing and Programming: 6 weeks
On-site Installation: 3 weeks (during scheduled production shutdown)
Commissioning and Testing: Completed within the shutdown window

Results & Benefits

Energy Efficiency

Significant energy savings achieved through implementation of 27 VFDs with optimized motor control
Modulating burner control in both ovens provides precise heat management, reducing gas consumption and improving temperature uniformity
Automatic pressure regulation of tunnel spraying pumps eliminated energy waste from over-pressurization
Variable speed operation across all conveyors and process equipment matched actual production requirements

Reliability & Maintenance

Greatly improved system reliability with modern, supported components
Spare parts readily available from current manufacturer product lines
IO-Link diagnostics enable predictive maintenance and rapid troubleshooting
Accurate documentation ensures future maintenance efficiency

Operational Improvements

Much easier process control through intuitive HMI interface
Better process visibility with real-time monitoring
Precise temperature control in ovens via modulating burners for consistent product quality
Improved treatment process control for better coating/finishing results
Coordinated system operation improves throughput and reduces waste

System Architecture

The Siemens S7-1512SP PLC provided the processing power needed to coordinate all 27 drives, manage multiple process zones (ovens, pretreatment, degreasing), and implement advanced control algorithms while maintaining deterministic real-time performance.

Waarom kiezen voor Prolink Engineering?

Bij Prolink Engineering krijgt u meer dan een engineeringbureau. Wij combineren electrical engineering met expertise in industriële automatisering, bordenbouw en installatietechniek. Daardoor ontwerpen we oplossingen die niet alleen technisch correct zijn, maar ook praktisch uitvoerbaar en onderhoudsvriendelijk.