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MODERNIZATION GOALS AND REQUIREMENTS

 
 
 

MODERNIZATION AND INTEGRATIONIMPLEMENTATION STAGES

 

The modernization and integration process typically includes:

  • Audit of the existing installation – assessment of technical condition, functionality, and documentation.

  • Concept development and technology selection – choosing controllers, drives, communication protocols, and software platforms.

  • Modernization works – installation of new components, removal of outdated elements, and completion of wiring/connection works.

  • Software integration – configuration of PLC controllers, SCADA systems, databases, and user interfaces.

  • Testing and industrial commissioning – verification under full process load.

  • Operator training and as-built documentation.

AUTOMATIONSYSTEM INTEGRATION

 

Integration involves connecting various devices, systems, and applications into a unified architecture that facilitates data exchange and coordinated process management. This is achieved using standard communication protocols such as PROFINET, EtherCAT, Modbus TCP, OPC UA, and MQTT, along with SCADA platforms and advanced MES systems.

Effective integration leads to:

  • centralized supervision and diagnostics,

  • enhanced transparency of production data,

  • simplified identification of root causes of failures,

  • adoption of predictive maintenance strategies,

  • the capability to monitor and control systems remotely.

Modernization of automation systems primarily arises from the necessity to enhance production reliability and efficiency. The most frequent motivations for implementing such changes include:

  • Replacement of outdated controllers, sensors, or drive systems that are no longer supported by manufacturers.

  • Improvement of the quality and stability of technological processes.

  • Enhancement of machine and personnel safety, in compliance with current standards and regulations.

  • Reduction of energy consumption and usage of operational materials.

  • Adapting industrial facilities to Industry 4.0 requirements, including integration with MES/ERP systems and process data analysis.

Modernization and integration of industrial automation systems are crucial for maintaining production continuity and supporting the growth of industrial facilities.

Advancing technologies, shifting market demands, and rising costs of downtime are prompting companies to increasingly take steps to upgrade existing control systems, enhance their efficiency, and incorporate them into a unified process management framework.

SYSTEM MODERNIZATION AND INTEGRATION

BETTER QUALITY CONTROL

HIGHER LEVEL OF WORKPLACE SAFETY

MINIMIZED DOWNTIME AND BREAKDOWNS

HIGHER PRODUCTION FLEXIBILITY

LOWER OPERATING COSTS

BENEFITS OF MODERNIZATION AND INTEGRATION

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