The Modernization Journey - Using IAB to Maximize Value & Reduce Cost

Summary

This presentation discusses the importance of modernizing control systems, focusing on Rockwell Automation products such as the Slick 500. The session highlights the challenges posed by obsolete components, unplanned downtime, and the need for proactive system upgrades. Three methods of converting older systems like the Slick 500 to newer Compact Logix setups are explored. The session also introduces tools like Integrated Architecture Builder, which aids in migration and compatibility. It emphasizes the financial and operational benefits of modernization, including reducing downtime and avoiding parts scarcity, while also preparing engineers for upcoming changes in control systems.

Takeaways

• 😀 Modernizing control systems is essential to avoid outdated, discontinued parts that could lead to unplanned downtime and compatibility issues.
• 😀 Product life status for Rockwell and Allen Bradley systems is categorized as Active, Active Mature, End of Life, and Discontinued, helping engineers assess product availability and plan upgrades.
• 😀 Older systems, like the Slick 500 family, have been in operation for decades but may soon face end-of-life status, requiring migration to more modern systems.
• 😀 Unplanned downtime can be costly, and many manufacturing plants experience reactive downtime due to outdated components or a lack of proactive maintenance.
• 😀 Upgrading systems can be justified by the high cost of downtime, which often exceeds the cost of an upgrade or modernization.
• 😀 Training on newer technologies is becoming more widespread, with younger engineers having less experience with older systems like the Slick 500.
• 😀 The Integrated Architecture Builder (IAB) software from Rockwell can assist in migrating systems like the Slick 500 to Compact Logix, saving time and costs.
• 😀 A physical inventory of existing systems, including part numbers and configurations, is crucial for understanding the current system's status and planning upgrades.
• 😀 For older systems, it's essential to avoid investing further in parts or components that are nearing end-of-life and won't receive firmware updates.
• 😀 Methods for upgrading include replacing old processors with new ones, using adapters to ensure compatibility with existing wiring, and validating the migration through software tools like IAB.

Q & A

Why is it important to modernize a control system?

Modernizing a control system helps avoid discontinued parts, reduce downtime caused by outdated components, and prevent compatibility issues with newer software and hardware. It also ensures better tech support and prevents the risk of unplanned downtime.

What does 'product life status' mean in the context of Rockwell and Allen-Bradley products?

Product life status refers to the lifecycle stages of a product, categorized as active, active mature, end of life, and discontinued. Active means the product is still in production and fully supported, while discontinued means it is no longer manufactured, and support is limited.

How can you determine the life cycle of your product?

You can check the product life cycle through Rockwell's official website, where products are listed with their life status. Additionally, performing a physical inventory of the equipment and consulting with installation-based evaluations (IBES) can provide insights into the status of your products.

What is Integrated Architecture Builder, and how is it used in control system modernization?

Integrated Architecture Builder is a free software tool from Rockwell used to design, validate, and aid in control system migrations. In this context, it is used to migrate from older systems like the Slick 500 to newer systems like CompactLogix, helping users plan and execute the upgrade.

What are the benefits of using Integrated Architecture Builder?

The tool helps users visualize and validate their system design, select compatible components, and ensure proper communication between system parts. It also simplifies the migration process by providing clear guidance on necessary equipment and wiring, ultimately reducing downtime and costs.

Why is downtime so costly in manufacturing environments?

Downtime in manufacturing causes disruptions that can affect production schedules, lead to financial losses, and incur high repair and replacement costs. The longer a system is down, the more costly it becomes in terms of lost productivity and delayed deliveries.

What are the three methods for converting a Slick 500 to CompactLogix?

The three methods are: 1) Direct conversion where old cards are replaced with new ones, 2) Using an adapter to connect old IO cards to a new system, and 3) Replacing only the processor while keeping the old IO cards in place.

What challenges do older control systems face regarding modern PCs and software?

Older systems may struggle with compatibility issues when newer PCs and software are used. For instance, older software may not run on new operating systems, and physical ports like serial ports are no longer common on modern PCs, requiring workarounds like virtual machines to run legacy programs.

What does it mean when a product goes from 'end of life' to 'discontinued' in Rockwell's product life cycle?

When a product reaches 'end of life,' it means Rockwell will stop actively supporting or manufacturing it, typically within one or two years. Once discontinued, the product will no longer be made, and support will be minimal, with only remaining inventory available for sale.

What are some key considerations when selecting IO cards for control system upgrades?

When selecting IO cards, it is essential to ensure they are not discontinued and are compatible with the new system. The cards should meet the technical specifications required for the system, and older models that no longer have available support or parts should be avoided.