In today’s world of computer-based data acquisition and controls systems, mechanical components often outlive the electronics in the system. When this happens, the tester may function correctly but the components used to control it are out-of-date, unsupported, and could lead to extensive downtime should they fail. At this point, decisions need to be made about the system’s future.
The first step in test cell modernization is to know what you have by reviewing the documentation. Then answer the following questions:
Does the system have an updated set of electrical drawings so that someone can determine how the system was designed and what components are in it?
Is there an up-to-date test specification that tells how the system executes a test?
If the answer is no, you will need a way to document the system enough so that you know what is there and what it does. From here, you should make a list of each component or sub-system and then work with your vendors to determine which parts are supported and which ones you will need to replace. When going through this process, look at lead times of components as well as accuracy and performance requirements. While you are updating the control and data acquisition system, this is a good time to consider what additional system capabilities you could add by replacing older sensors, actuators, drives, or other devices that may increase performance benefits.
Another consideration is determining if you can combine separate sub-systems to reduce overall system complexity. Older systems commonly include separate control, data collection, and safety systems. Many times you can combine these items to ensure safe, real-time control within a PC-based system that collects and analyzes the data. Genuen’s INERTIA™ and RAPID products offer both a real-time controller and a PC as a single integrated system. You can also consider PLCs that offer integrated motion controls or drives and have logic capabilities for machine control. These solutions are often more cost effective and easier to maintain than separate systems.
Another consideration that is often overlooked is the test system infrastructure. This could include things like building ventilation, AC power, cooling water, and cell safeties. Spend time looking at the wiring on the machine; if problems like electrical noise exist, you should determine if the system meets current best practices or if complete re-wiring is necessary. Look for things like worn cables and wires, missing labels, AC/DC signals mixed together, or sensors that require AC power that could be replaced with modern 24 VDC devices. Even if you do not need to change the mechanical system, replacing old wiring is a good idea.
When performing test cell modernization, the planning phase is critical. Take the time to make sure you know what you have and what you need to change. Make sure you take ample time to step back and consider how things have changed since the cell was implemented. When establishing the plan, make sure you include replacing all worn and out-of-date parts so that you now have a modern system that delivers the benefits you need.