Retrofitting existing control systems
Many of the machines and systems used in automated production rely on older, sometimes analog control system generations, which continue to perform reliably and without any problems. Nevertheless, the discontinuation of a reliable control system in existing machines and systems has caused concern among many users. However, these and the majority of existing control technologies can remain in use. The retrofit and conversion to the 300S+ control system from Yaskawa enables this functionality.
As the control technology in existing machines and systems ages, it no longer meets the required standards for state-of-the-art technology and often fails to meet today's safety standards. In addition, obtaining spare parts is challenging, and in some cases, it is no longer feasible due to product discontinuation. This can lead to unexpected downtimes and high maintenance costs.
However, in order to achieve sustainability within the company, it is essential to utilise existing technology for as long as possible. The prerequisite for this is a retrofit. Replacing old or discontinued hardware components—such as the control system—allows machines to be brought up to the current state of the art. This solution presents a dual advantage in terms of both ecological and economic considerations. The existing systems and production processes are undergoing technical upgrades to ensure that reliability, efficiency, competitiveness, and future-proofing are once again guaranteed.
Control system 300S+
Such a retrofit is possible, for example, with the 300S+ control system from Yaskawa. Since its inception in the 1990s, it has evolved into a dominant system in the market. Over 1.5 million components of the high-speed control system have now been installed in countless machines worldwide. The latest 300S+ model is notable for its speed: it is around ten times faster than comparable systems. The PLC CPUs offer a significantly higher memory size of up to 8 MB (fully retentive) and a range of additional benefits over previous models, all at a competitive price point. Against this background, the 300S+ system with SPEED7 technology is positioned as a reliable and robust controller for even the most demanding applications.
Finally, the system offers not only exceptional processing speeds and capacities, but also a further advantage: The 300S+ series, whether a compact CPU or a fully equipped PLC automation system, is designed to meet a wide range of requirements and applications. It offers particular flexibility, for example, through the inclusion of suitable front connectors for the integrated I/O channels.
Retrofit made easy
This proven technology has a long history of reliable performance and is backed by a substantial inventory of spare parts. This ensures a safe, smooth production process and trouble-free operation. Replacement and commissioning activities are scheduled during a planned shutdown to facilitate a rapid restart of production. The machine's output and performance are enhanced, resulting in increased productivity and quality while also extending its service life. Furthermore, enhanced performance, increased productivity, and superior quality are realized. The machine has been designed with maintenance and user-friendliness in mind, resulting in an extended overall service life. The use of fanless CPUs also contributes to reducing the energy requirements of the control technology.
This flexibility presents an opportunity to explore new solutions that could potentially replace existing ones. In light of the ongoing developments in the automation sector, this represents a suitable option for those seeking to retrofit existing control systems. Many system series from market-leading manufacturers have been successfully in use for many years.
It is evident that functionality, availability, practical experience, and spare parts management are not the sole reasons behind the continued use of the system by numerous operators and maintenance personnel. While digitalization at the management level continues to progress rapidly in automated production, older, partially analog generations of control systems are still in use in many machines and systems. From the perspective of many operators and maintenance staff, the advantages of continued use, including functionality, availability, practical experience, spare parts management, and other benefits, make this a compelling option.
Multiple options
There are multiple general options for retrofitting the existing control system, even in the event that the original manufacturer is phasing out the system or has already discontinued it. Furthermore, the system is designed to meet the highest standards in terms of intelligent memory management, data security, and comprehensive communication capabilities via modern protocols, including an integrated Ethernet connection and a wide range of supported buses. A variety of on-board communication interfaces, including Ethernet, PROFIBUS-DP, and serial RS485, as well as optional extensions, ensure excellent connectivity and integration into existing networks, providing customers with a high level of flexibility and compatibility.
In general, the 300S+ controllers can be programmed via two proven platforms: STEP7 and the TIA Portal from Siemens, or the Yaskawa WinPLC7 software. This provides complete freedom to develop and maintain projects as required. The 300S+ system offers advanced and reliable memory management, including automatic backup functions, with external memory options via MMC/SD cards up to 2 GB and a battery-backed RAM.
Furthermore, IOs and accessories from Yaskawa are fully compatible with the previously market-dominating system. All hardware components can be replaced on a one-to-one basis and operated in parallel during mixed operations. Moreover, the CPUs can remain in use with minimal changes to functionality, eliminating the need to replace existing software. Yaskawa offers comprehensive support for the corresponding adaptations in the CPUs, including the "TASK FORCE 300" service, download options, and other useful functions on the Yaskawa website.