A Step-By-Step Approach to Retrofit and Automation of PCB Machines Using PLC

Abstract

Retrofitting of machine has today become very popular for manufacturing and processing in small, medium and large industries as demand for high quality, greater efficiency and automated machines increase by day. It offers numerous advantages in the area of cost effectiveness and higher productivity. Technological upgradation and refurbishing of old machine restore them close to their original performance levels, contain capital costs, add value to the process and address obsolescence. Retrofitting can be achieved through a phased approach from the perspective of comprehension or through step-by-step approach to automate, understanding the needs thus employing the best control system to achieve the desired result. Simplification of engineering practices and precision control requirements of manufacturing processes by absorbing technological changes can result in significant cost savings. The most cost-effective way which can pay rich dividends in the long run is adopting flexible automation via a planned approach towards integrated control systems. It requires a conscious effort on the part of plant managers to identify areas where automation can result in better deployment/utilization of human-machine-interface and its implementation to achieve higher productivity. This paper highlights a case study of retrofitting and automation of a Del Monte’s old FMC Caser Machine (Model 7 Non Shock Caser) with a Programmable Logic Controller, PLC, based control system using a step-by-step approach for a successful performance to address problem of: obsolescence, reduced productivity, increased down time, increased repairs and increased maintenance costs. Keywords: Electro-Pneumatics, Industrial Automation, Programmable Logic Controller (PLC), Printed Circuit Board (PCB), Retrofitting of Machine