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• Modernization works – installation of new components, removal of outdated elements, and completion of wiring/connection works.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

Integration involves connecting various devices, systems, and applications into a unified architecture that enables data exchange and coordinated process management. For this purpose, standard communication protocols such as PROFINET, EtherCAT, Modbus TCP, OPC UA, and MQTT are used, along with SCADA platforms and higher-level MES systems.

Effective integration results in:

• centralized supervision and diagnostics,

• improved transparency of production data,

• easier identification of root causes of failures,

• implementation of predictive maintenance strategies,

• the ability to monitor and control systems remotely.

Modernization of automation systems primarily results from the need to increase production reliability and efficiency. The most common reasons for implementing such changes include:

• Replacement of obsolete 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 accordance with current standards and regulations.

• Reduction of energy consumption and operating materials usage.

• 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 a key element in maintaining production continuity and supporting the development of industrial plants.

Advancing technologies, changing market requirements, and increasing downtime costs are driving companies to increasingly undertake actions aimed at upgrading existing control installations, optimizing their performance, and integrating them into a coherent process management environment.

BETTER QUALITY CONTROL

REDUCED DOWNTIMEAND BREAKDOWNS

HIGHER PRODUCTION FLEXIBILITY

LOWER OPERATING COSTS

BENEFITS OF MODERNIZATION AND INTEGRATION

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