Project F

Machine Upgrade – Safety & Control System Enhancement

Project Overview

The customer required an upgrade to the machine’s safety and control infrastructure. While the mechanical system remained largely unchanged, the existing electrical and safety systems were outdated and lacked modern diagnostics. The objective was to deliver a safer, more reliable, and fully integrated control solution.

The Challenge

Outdated safety wiring and shared alarm structure
Limited diagnostic feedback from emergency stops and guard switches
Existing mechanical sections still functional but connected to an obsolete control system
No modern HMI interface
Lack of unified, up-to-date electrical documentation

The customer needed improved safety monitoring, clearer fault identification, and a refreshed control interface without altering the machine’s core mechanical functions

Our Solution

We upgraded the full safety and control architecture, integrating modern technology while retaining usable machine hardware

1. Safety System Rewire

All emergency stops and guard switches were rewired to individual safety inputs
Each device was assigned a dedicated alarm for faster troubleshooting
Fully integrated into a programmable safety controller for complete system monitoring

2. PLC Integration of Existing Machine Sections

Some sections of the machine remained mechanically unchanged, but all required devices and sensors were reconnected to the new PLC to ensure reliable, unified control.

3. New HMI & Motion Control