Problem:
A Beryllium processing facility relied on two large DC motors for its metal forming operation—one to load raw material into the forming machine and the other to power a bridle, ensuring proper tension, speed, and torque for achieving the correct metal thickness.
The motors were controlled by obsolete programmable logic controllers (PLCs), variable frequency drives (VFDs), and human machine interfaces (HMIs) that were no longer supported within the Rockwell Automation product portfolio. If the system failed, production could have been down for 4–6 months, resulting in major financial losses.
Solution:
The obsolete controls were replaced with modern Rockwell Automation ControlLogix PLCs and FactoryTalk Optix HMIs. Working closely with the customer, the project was structured in two phases over six months to align with budget constraints while minimizing disruption.
Outcome:
The plant now operates with modern, fully supported automation equipment. Replacement parts are readily available, and the risk of extended production downtime has been eliminated, ensuring continued safe, reliable, and efficient metal forming operations.
